EP0203198B1 - Verfahren zum Verstärken eines metallischen Artikels - Google Patents

Verfahren zum Verstärken eines metallischen Artikels Download PDF

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Publication number
EP0203198B1
EP0203198B1 EP19850905667 EP85905667A EP0203198B1 EP 0203198 B1 EP0203198 B1 EP 0203198B1 EP 19850905667 EP19850905667 EP 19850905667 EP 85905667 A EP85905667 A EP 85905667A EP 0203198 B1 EP0203198 B1 EP 0203198B1
Authority
EP
European Patent Office
Prior art keywords
insert
alloy
plating
plating bath
aluminum
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 - Lifetime
Application number
EP19850905667
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English (en)
French (fr)
Other versions
EP0203198A4 (de
EP0203198A1 (de
Inventor
Masahiko Kakefuda
Yasuo 4-6 Akebonodai 1-Chome Kondo
Minoru 7-4 Koazaumegahata Imai
Nobuyoshi Houjoh
Fumio Morimune
Tadao 19 Matsumuroyamazoecho Yamashita
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.)
Mitsubishi Motors Corp
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Mitsubishi Motors Corp
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
Priority claimed from JP59234595A external-priority patent/JPS61115658A/ja
Priority claimed from JP24766585A external-priority patent/JPS62107854A/ja
Application filed by Mitsubishi Motors Corp filed Critical Mitsubishi Motors Corp
Publication of EP0203198A1 publication Critical patent/EP0203198A1/de
Publication of EP0203198A4 publication Critical patent/EP0203198A4/de
Application granted granted Critical
Publication of EP0203198B1 publication Critical patent/EP0203198B1/de
Anticipated expiration legal-status Critical
Expired - Lifetime 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
    • B22D19/00—Casting in, on, or around objects which form part of the product
    • B22D19/0036—Casting in, on, or around objects which form part of the product gears
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D19/00—Casting in, on, or around objects which form part of the product
    • B22D19/0009—Cylinders, pistons

Definitions

  • the present invention relates to a method for reinforcing a metallic article, according to the preamble of claim 1, wherein an aluminum alloy, and FRM (fiber reinforced material), steel, a Ti alloy, an Ni alloy, a Co alloy or the like is inserted in an aluminum alloy.
  • FRM fiber reinforced material
  • Aluminum alloy castings have the advantages of being lightweight, being usable in die-cast casting, molten-metal forging, and low-pressure casting, and having a high productivity. However, since they have lower strength, they have lower wear resistance, and the like, that iron castings, and their application range is limited.
  • a high-strength material such as an iron-based material
  • an iron-based material is inserted at a position of an aluminum alloy casting which requires high strength.
  • simple insertion for example, when an iron-based material is inserted in an aluminum alloy, a non-welded portion remains at the iron-aluminum alloy boundary.
  • alphine treatment As a method of eliminating such a non-welded portion and diffusion welding the iron-aluminum boundary, alphine treatment is known.
  • the alphine treatment requires a great deal of labor, and increases the cost and weight of the resultant material.
  • a precleaned higher melting point portion is provided with an irregular surface by submitting said portion to high frequency sonic vibrations in a molten bath of aluminum or aluminum alloy. After the higher melting point portion has been wetted with an aluminum layer, it is removed from the bath and placed in a mold cavity into which aluminum is cast.
  • a method is described in US patent 3 401 026 to WALKER ET AL, upon which the preamble of claim 1 is based.
  • an inert made of material such as an aluminum alloy, an FRM, steel, a Ti alloy, an Ni alloy, a Co alloy or the like is subjected to a pre-treatment, such as water rinsing, degreasing, pickling, drying, and the like.
  • a pre-treatment such as water rinsing, degreasing, pickling, drying, and the like.
  • the insert is then dipped in a plating bath, and is plated while oscillating an oscillating plate arranged near the insert in the plating bath. Subsequently, the insert is inserted in an insertee, such as an insertee composed of an aluminum alloy.
  • the present invention is characterized in that the insert is placed with respect to the oscillation plate so that the gap therebetween is 0.5 mm or less, that the oscillation plate, the plating bath and the insert are submitted to ultrasonic oscillations until an oxide film on said insert is removed and that the plating of said insert is continued until the plating layer deposited on said insert has reached a thickness of 5 um.
  • the plating bath is oscillated to remove the surface oxide of the insert and to form a uniform plating layer.
  • the insert is inserted in an insertee, such as an aluminum alloy, with the plating-layer between them. Next, the insert and the insertee are completely welded together, and a diffusion welding region is formed between the two materials.
  • the insert and insertee material are securely bonded together, and an inserted article having a satisfactory strength can be manufactured. Since the plating bath need only be oscillated, the manufacturing process is easy, and the cost is low.
  • Fig. 1 is a sectional view of a plating device used in Example 1 of the present invention
  • Fig. 2 shows a tapered shaft manufactured by the method of Example 1
  • Fig. 3 is a microphotograph (x 100) of a boundary portion between insert and insertee of an inserted article manufactured by the method in Example 1 of the present invention
  • Fig. 4 is a microphotograph (x 100) of a boundary portion between insert and insertee of an article of a Comparative Example obtained by inserting an insert in an insertee without plating the former [the article corrsponding to the non-preheated, no treatment section for the Comparative Example in the table]:
  • Fig. 3 is a microphotograph (x 100) of a boundary portion between insert and insertee of an inserted article manufactured by the method in Example 1 of the present invention
  • Fig. 4 is a microphotograph (x 100) of a boundary portion between insert and insertee of an article of a Comparative Example obtained by inserting an insert in an
  • FIG. 5 is a microphotograph (x 100) of a boundary portin between piston main body 13 and anti-wear ring 12 of a piston of Example 2;
  • Fig. 6 is a sectional view of mold 19 in Example 5;
  • Fig. 7 is a microphotograph (x 100) of a boundary portion between steel wire 14 and aluminum alloy 20 of test piece No. 4 of Example 5;
  • Fig. 8 is a microphotograph (x 100) of a boundary portion between steel wire 14 and aluminum alloy 20 of test piece No. 6 of Example 5;
  • Fig. 9 is a sectional view of an engine connecting rod of Example 5;
  • Fig. 10 is a perspective view of cam 18 of Example 6;
  • Fig. 11 is a sectional view of a cam shaft of Example 6;
  • Fig. 12 is a sectional view of a piston of Example 7;
  • Fig. 13 is a sectional view of a cylinder head of Example 4;
  • Fig. 14 is a sectional view of an engine including a cylinder head of Example 8; and
  • Fig. 15 is a front view of a rocker arm of an internal engine according to the present invention.
  • An insert is prepared from JISA2024S aluminum alloy.
  • the insert is subjected to cleaning/drying, i.e., a pre-treatment in the order of rinsing with water, degreasing, rinsing with water, pickling, rinsing with water, and drying by a pre-treatment device.
  • cleaning/drying i.e., a pre-treatment in the order of rinsing with water, degreasing, rinsing with water, pickling, rinsing with water, and drying by a pre-treatment device.
  • Plating is then performed in plating device 1 shown in Fig. 1.
  • Plating device 1 consists of solder melting furnace 2 and ultrasonic wave oscillator 3.
  • Furnace 2 consists of solder tank 5 containing plating bath 4 at its upper portion, and heating section (heating coil) 6 arranged below tank 5 for heating it.
  • One of oscillating plates 8 branching in a Y-shape is fixed to oscillation horn 7 of oscillator 3, and the other plate 8 is dipped in plating bath 4 in tank 5.
  • Insert material 9 is inserted between two oscillating plates 8 and is located with a gap of 1.0 mm with respect to two plates 8 by the surface tension of the plating bath.
  • Insert 9 is plated under the following conditions:
  • Insert 9 plated with Zn-5A alloy is set in a mold of a casting device (not shown). Molten AC4B aluminum alloy is gravity-cast as an insertee, thereby molding tapered shaft 10 shown in Fig. 2. Tapered shaft 10 consists of AC4B main body 11 and insert 9.
  • Insert materials were molded from JISA2024S material and were respectively subjected to non-treated Zn plating, Sn plating, kanigen plating, and molten aluminum solder plating. Thereafter, each material was inserted in AC4B aluminum alloy to manufacture a tapered shaft (similar to Example 1).
  • Example 1 The welding performance and pressure/absence of insert loss in Example 1 and the Comparative Example were tested. The obtained results are shown in Table 1.
  • Example 1 provides better results than the Comparative Example, and no insert loss is experienced.
  • the insert is subjected to ultrasonic oscillation while molten aluminum plating is performed, thereby removing the oxide layer formed on the surface of the insert and forming a uniform eutectic layer of aluminum-aluminum solder.
  • the eutectic layer has a low melting point, easily melts in an insertee molten aluminum alloy bath, and mixes therewith.
  • An anti-wear ring of a piston for a diesel engine was prepared as an insert. Following the same procedures as in Example 1, Zn-5AI solder was melted and used to plate the ring, the plated ring was set in a mold, and AC8A aluminum alloy as an insertee was injected into the mold to form a piston. The casting temperature was 700°C.
  • the anti-wear ring consisted of ADC10 aluminum alloy in which an Si 3 N 4 powder was dispersed.
  • a microphotograph (x 100; Fig. 5) of a texture at a boundary between anti-wear ring 12 and piston main body 13 cast from AC8A aluminum alloy reveals that no nonwelded portion remains between anti-wear ring 12 and piston main body 13, and that the two materials are completely welded.
  • a cylinder liner of ADC10 aluminum alloy in which an Si 3 N 4 powder was dispersed was prepared, and was plated with aluminum alloy solder using Zn-5AI alloy as in Example 1.
  • the obtained cylinder liner was set in a mold, and molten aluminum alloy was injected into the mold to cast a cylinder block main body, thereby obtaining a cylinder block in which the cylinder block is inserted in the cylinder block main body.
  • a roof member for constituting a refractory combustion chamber wall of a cylinder head was prepared from an FRM having a great thermal fatigue strength (i.e., containing long carbon fiber and JISA6061 aluminum alloy as a matrix).
  • the roof member was plated with aluminum alloy solder, the plated roof member was set in a mold, and an aluminum alloy as an insertee was injected into the mold to cast a cylinder main body.
  • roof member 32 was inserted in cylinder head main body 31 to complete cylinder head 33.
  • Each tensile strength test piece 15 has a size of 7 (diameter) x 32 mm at a parallel portion thereof (marked distance: 25 mm).
  • a chuck portion thereof had threads of M12 and P1.5 so as to eliminate the influence of chucking on the insertee in the tensile strength test.
  • Fig. 7 corresponds to test piece No. 4 in Table 2.
  • MASIC steel wire 16 having a diameter of 4.0 mm was subjected to plating with aluminum solder under the same conditions as test piece No. 4 in Example 4. After the wire was preheated to 300°C, it was set in a mold and ADC10 aluminum alloy was cast by the non-porous die cast method, thereby molding connecting rod 17 for an automobile engine as shown in Fig. 9.
  • the resultant connecting rod 17 exhibited about 50% improvement in strength as compared to that when a similar wire was not inserted in MASIC steel.
  • the MASIC steel and ADC10 material were completely welded together through the aluminum solder.
  • Internal engine cams 18 shown in Fig. 10 were made by an iron-based sintered alloy.
  • the side and inner circumferential surfaces of cams 18 were pre-treated and plated after the same procedures as in Example 1.
  • aluminum solder-plated cams 18 were preheated to 300°C, they were set in a mold for casting an internal engine cam shaft, and ADC10 aluminum alloy was injected into the mold and cast by the die cast method, thereby mounting cams 18 on shaft 19, as shown in Fig. 11.
  • Cams 18 and shaft 19 were completely welded together through the aluminum solder.
  • Diesel engine anti-wear ring 21 of Ni-resist cast iron was plated with aluminum solder in the same manner as test piece No. 4 in Example 5. After the anti-wear ring was preheated to 300°C, it was set in a mold, and ADC10 aluminum alloy was injected by gravity casting to mold diesel engine piston 22 as shown in Fig. 12.
  • the anti-wear ring and ADC10 aluminum alloy were completely welded together through the aluminum solder.
  • a cylinder liner was molded with ADC10 aluminum alloy in which an Si 3 Ni 4 powder was dispersed.
  • the cylinder liner was pre-treated and plated with pure zinc under ultrasonic oscillation.
  • the plating conditions were as follows:
  • the zinc-plated cylinder liner was inserted into a mold, and molten aluminum alloy (ADC10 alloy) was injected into th mold to mold cylinder block 35, in which cylinder liner 34 was inserted as shown in Fig. 14.
  • ADC10 alloy molten aluminum alloy
  • the zinc plating bath temperature was 500°C
  • the plating time was 5 minutes
  • the ultrasonic oscillation application time was 5 seconds.
  • the ultrasonic oscillation frequency is 18 kHz.
  • the ultrasonic oscillation frequency can be within a range of 1 to 1,000 kHz, and preferably 1 to 100 kHz.
  • the ultrasonic oscillation frequency is below 1 kHz, the repeating number within a unit time is small, the oxide film formed on the surface of the material to be plated cannot be removed, complete plating cannot be performed, the plating layer is easily peeled off, and a uniform plating layer cannot be formed.
  • the ultrasonic oscillation frequency exceeds 1,000 kHz, the plating bath cannot follow oscillation of the oscillation plate, and the plating bath is peeled from the surface of the oscillation plate to cause cavitation, which damages the oscillation plate.
  • the plating film thickness is set to be 50 pm or 100 ⁇ m. According to the present invention, the plating film thickness is preferably within a range of 5 to 300 p m, and in particular, 30 to 100 um. When the plating film thickness is below 5 um, welding with the aluminum alloy during the insertion process is incomplete. Since a complete welding between the insert and insertee can be achieved with plating film thicknesses of 300 urn or less, plating exceeded a thickness of 300 ⁇ m is superfluous.
  • the amplitude of the oscillation plate was 20 pm.
  • the amplitude is preferably within a range of 5 to 35 p m.
  • the amplitude is less than 5 um, sufficient energy cannot be applied to the plating to the plating bath, the oxide formed on the surface of the insert material cannot be removed, and a uniform plating layer cannot be formed.
  • the amplitude exceeds 35 p m, the plating bath cannot follow movement of the oscillation plate, and cavitation may cause damage to the oscillation plate.
  • the distance between the oscillation plate and the plating surface of the insert was 0.1 mm.
  • the distance can be 0.5 mm or less to allow the presence of the plating bath between the oscillation plate and the insert.
  • wave force of the plating bath applied by oscillation of the oscillation plate is not sufficiently transmitted to the insert, and a uniform, strong plating layer cannot be formed.
  • the plating bath composition was Zn-Al alloy or pure zinc.
  • any aluminum solder according to JISZ3281, SAL-BQZ, or SAL-CRZ can be used.
  • a cadmium-silver alloy [Cd: 95%, Ag: 5% (by weight)]
  • a tin-zinc alloy [Sn: 85%, Zn: 15% (% by weight)]
  • Sn 85%, Zn: 15% (% by weight
  • the insert material was an aluminum alloy, stainless steel, high strength steel, cast iron, an FRM (an aluminum alloy containing carbon fiber), or an iron-based sintered alloy.
  • iron steel including stainless steel or heat-resistant steel
  • a titanium alloy a nickel alloy, a cobalt alloy, an FRM using an aluminum or zinc alloy as a matrix, or the like can be used.
  • constituent parts such as a connecting rod were prepared.
  • constituent parts such as a crank shaft, a rocker arm, an automobile suspension part (e.g., a suspension arm), a differential gear carrier, a disk brake caliper, and various gears can also be prepared.
  • a rocker arm consists of chip 37 of an iron-based sintered alloy and rocker arm main body 36 of an aluminum alloy, and chip 37 is in slidable contact with a cam, as shown in Fig. 15.
  • a Zu-Al alloy or the like is plated on the outer surface of chip 37 under ultrasonic oscillation, and is inserted in rocker arm main body 36.
  • a suspension arm steel is inserted in the longitudinal direction thereof, a bush, as a mount portion of the arm to the vehicle body, and a joint member to a wheel are inserted, the outer surface of the wire is plated by the method of the present invention, the joint surface between the steel outer cylinder of the bush and the joint member is plated by the method of the present invention, and the three members are inserted in an aluminum alloy to prepare a suspension arm.
  • the method of the present invention is used in the same manner as for a mount bush to the vehicle body and a suspension arm.
  • a wire, an FRM or the like is inserted by the method of the present invention.
  • any one of sand mold casting, mold gravity casting, low-pressure casting, die-casting, molten metal forging and the like can be used.
  • the insert when the insert is an iron-based material, it is preheated before insertion.
  • preheating is not always necessary, and can be performed at 400°C or lower. Whether or not to perform preheating can be determined in accordance with the material of the insert used.
  • plating is performed while ultrasonic oscillation is applied to the plating bath.
  • the gap between the insert and oscillation plate is set to be 0.1 mm. However, the gap can be 0.5 mm or less: the plating bath need only be present between the two materials.
  • oscillation applied to the plating bath by the oscillation plate is reflected by the insert.
  • the reflected wave is amplified with the oscillation energy by the oscillation plate, and the amplified energy reaches the surface of the insert to remove the oxide on the surface of the insert and to form a uniform plating layer.
  • the gap exceeds 0.5 mm, the wave reflected by the insert is attenuated.
  • the oscillation wave cannot have sufficient oscillation energy. Therefore, oxide on the surface of the insert material cannot be completely removed, a uniform plating layer cannot be formed, and a non-welded portion is formed between the insert and insertee.
  • the present invention can be applied to the manufacture of cylinder heads, pistons, connecting rods, cam shafts pistons, and cylinder blocks, of engines, crank shafts, rocker arms, suspension arms, differential gear carriers, disk brake calipers, and various gears.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Cylinder Crankcases Of Internal Combustion Engines (AREA)
  • Electroplating Methods And Accessories (AREA)
  • Valve-Gear Or Valve Arrangements (AREA)
  • Molten Solder (AREA)

Claims (12)

1. Verfahren zur Verstärkung eines Metallgegenstandes durch Einsetzen eines hochfesten Materials, gemäß dem ein vorbehandelter Einsatz (9) in ein Beschichtungsbad (4) eingetaucht wird, das eine nahe dem Einsatz (9) angeordnete Schwingungsplatte (8) enthält, das Beschichtungsbad (4) durch die Schwingungsplatte (8) in Schwindungen versetzt wird und der eschichtete Einsatz in eine Aluminiumlegierung (11) durch Gießen der Legierung um den beschichteten Einsatz in einer Form eingebracht wird, dadurch gekennzeichnet, daß der Einsatz (9) bezüglich der Schwingungsplatte (8) so angeorndet wird, daß der Spalt dazwischen 0,5 mm oder weniger ist, daß die Schwindigungsplatte (8), das Beschichtungsbad (4) und der Einsatz (9) Ultraschallschwingungen ausgesetzt werden, bis der Oxidfilm auf dem Einsatz (9) beseitigt ist, und daß die Beschichtung des Einsatzes (9) fortgesetzt wird, bis die auf dem Einsatz (9) abgeschiedene Beschichtungsschicht eine Dicke von wenigstens 5 pm erreicht hat.
2. Verfahren nach Anspruch 1, dadurch gekennzeichnet, daß der Einsatz (9) selbst durch Schwingung des Beschichtungsbades (4) in Schwingungen versetzt wird.
3. Verfahren nach Anspruch 1, dadurch gekennzeichnet, daß die Schwingungsplatte (8) Ultraschallschwingungen mit einer Amplitude im Bereich von 5 bis 35 um unterworfen wird.
4. Verfahren nach Anspruch 1, dadurch gekennzeichnet, daß das Beschichtungsbad (4) aus Aluminiumlot besteht.
5. Verfahren nach Anspruch 1, dadurch gekennzeichnet, daß das Beschichtungsbad (4) aus reinem Zink besteht.
6. Verfahren nach Anspruch 1, dadurch gekennzeichnet, daß das Beschichtungsbad (4) aus einer Cadmium-Silber-Legierung besteht.
7. Verfahren nach Anspruch 1, dadurch gekennzeichnet, daß das Beschichtungsbad (4) aus einer Zinn-Zink-Legierung besteht.
8. Verfahren nach Anspruch 1, dadurch gekennzeichnet, daß nachdem der Einsatz (9) beschichtet ist, der Einsatz (9) auf eine Temperatur von 400°C oder darunter vorerhitzt und in eine Aluminiumlegierung (11) eingebracht wird.
9. Verfahren nach Anspruch 1, dadurch gekennzeichnet, daß die auf einer Oberfläche des Einsatzes (9) gebildete Beschichtungsschicht eine Dicke von 5 bis 300 pm hat.
10. Verfahren nach Anspruch 1, dadurch gekennzeichnet, daß die Schwingungsfrequenz 1 bis 1000 kHz ist.
11. Verfahren nach Anspruch 1, dadurch gekennzeichnet, daß der Einsatz aus dem aus der Gruppe gewählten Material hergestellt wird, die aus einem Eisenbasismaterial, einer Titanlegierung, einer Nickellegierung, einer Kobaltlegierung, einer Aluminiumlegierung, einem FRM mit einer Aluminiumlegierung als Matrix und einem FRM mit einer Zinklegierung als Matrix besteht.
12. Verfahren nach Anspruch 8, dadurch gekennzeichnet, daß der Einsatz aus einem Eisenbasismaterial hergestellt wird.
EP19850905667 1984-11-07 1985-11-07 Verfahren zum Verstärken eines metallischen Artikels Expired - Lifetime EP0203198B1 (de)

Applications Claiming Priority (4)

Application Number Priority Date Filing Date Title
JP234595/84 1984-11-07
JP59234595A JPS61115658A (ja) 1984-11-07 1984-11-07 鋳ぐるみ法
JP24766585A JPS62107854A (ja) 1985-11-05 1985-11-05 鋳ぐるみ方法とその装置および鋳ぐるみ品
JP247665/85 1985-11-05

Publications (3)

Publication Number Publication Date
EP0203198A1 EP0203198A1 (de) 1986-12-03
EP0203198A4 EP0203198A4 (de) 1988-04-26
EP0203198B1 true EP0203198B1 (de) 1991-01-30

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EP19850905667 Expired - Lifetime EP0203198B1 (de) 1984-11-07 1985-11-07 Verfahren zum Verstärken eines metallischen Artikels

Country Status (5)

Country Link
EP (1) EP0203198B1 (de)
AU (1) AU574541B2 (de)
DE (2) DE3590587C2 (de)
GB (1) GB2184048B (de)
WO (1) WO1986002862A1 (de)

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Publication number Publication date
AU574541B2 (en) 1988-07-07
GB2184048B (en) 1988-11-23
EP0203198A4 (de) 1988-04-26
GB2184048A (en) 1987-06-17
WO1986002862A1 (en) 1986-05-22
EP0203198A1 (de) 1986-12-03
DE3590587T1 (de) 1986-11-20
DE3590587C2 (de) 1988-06-23
GB8615801D0 (en) 1986-08-06
AU5068085A (en) 1986-06-03

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