EP0292777A1 - Method for manufacture of a ceramic coated metallic component - Google Patents

Method for manufacture of a ceramic coated metallic component Download PDF

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Publication number
EP0292777A1
EP0292777A1 EP88107493A EP88107493A EP0292777A1 EP 0292777 A1 EP0292777 A1 EP 0292777A1 EP 88107493 A EP88107493 A EP 88107493A EP 88107493 A EP88107493 A EP 88107493A EP 0292777 A1 EP0292777 A1 EP 0292777A1
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Prior art keywords
layer
aluminum
ceramic
ceramic layer
oxide
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Granted
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EP88107493A
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German (de)
French (fr)
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EP0292777B1 (en
Inventor
Mohamed Dr. Yarahmadi
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Interatom Internationale Atomreaktorbau GmbH
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Interatom Internationale Atomreaktorbau GmbH
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Priority to AT88107493T priority Critical patent/ATE55565T1/en
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    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
    • F01N13/00—Exhaust or silencing apparatus characterised by constructional features ; Exhaust or silencing apparatus, or parts thereof, having pertinent characteristics not provided for in, or of interest apart from, groups F01N1/00 - F01N5/00, F01N9/00, F01N11/00
    • F01N13/16—Selection of particular materials
    • 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
    • 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
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F02—COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
    • F02B—INTERNAL-COMBUSTION PISTON ENGINES; COMBUSTION ENGINES IN GENERAL
    • F02B77/00—Component parts, details or accessories, not otherwise provided for
    • F02B77/02—Surface coverings of combustion-gas-swept 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
    • F05C2201/04—Heavy metals
    • F05C2201/043—Rare earth metals, e.g. Sc, Y
    • 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
    • F05C2203/00—Non-metallic inorganic materials
    • F05C2203/08—Ceramics; Oxides

Abstract

Zur Herstellung einer sowohl vibrationsfesten als auch temperaturwechselbeständigen, wärmeisolierenden Keramikauskleidung in hohlen Bauteilen, z. B. Abgaskrümmern von Verbrennungskraftmaschinen wird ein Verfahren angegeben, bei dem auf einer Form (1) zunächst eine erste Keramikschicht (2) aufgebracht wird, auf diese anschließend eine sehr dünne Gleitschicht (3), z. B. aus Metall und auf diese wiederum eine zweite Keramikschicht (4), die durch Mikrofugen (5) in einzelne Felder geteilt wird. Durch Umgießen mit Metall (6) wird schließlich das Bauteil fertiggestellt. Bedingt durch die Fugen kann die zweite Keramikschicht besser den stärkeren Wärmedehnungen des Metallkörpers folgen. Ein weiterer Spannungsausgleich zwischen erster und zweiter Keramikschicht erfolgt über die duktile Gleitschicht.To produce a both vibration-resistant and temperature change-resistant, heat-insulating ceramic lining in hollow components, e.g. B. exhaust manifolds of internal combustion engines, a method is specified in which a first ceramic layer (2) is first applied to a mold (1), then a very thin sliding layer (3), z. B. of metal and this in turn a second ceramic layer (4), which is divided by microfuge (5) into individual fields. The component is finally completed by casting metal (6) around it. Due to the joints, the second ceramic layer can better follow the greater thermal expansion of the metal body. A further tension equalization between the first and second ceramic layer takes place via the ductile sliding layer.

Description

Die vorliegende Erfindung betrifft ein Verfahren nach dem Oberbegriff des 1. Anspruchs. In ihrer nicht vorveröffentlichten deutschen Patentanmeldung P 37 05 903.3 hat die Anmelderin ein Verfahren beschrieben, mittels dessen Gußteile aus metallischem Werkstoff mit einer eingegossenen glatten Auskleidung versehen werden können, z. B. sogenannte Portliner von Verbrennungs­kraftmaschinen. Hier werden auf einen verlorenen Kern mittels Flamm- oder Plasmaspritzen nacheinander Schichten aufgebracht, deren Zusammensetzung so variiert wird, daß allmählich von einer rein keramischen Zusammensetzung zu einer schließlich rein metallischen Zusammensetzung gelangt wird. An letztere kann zur Fertigstellung des Bauteiles eine beliebig dicke Schicht Metall angegossen werden. Durch den gradierten Übergang von Keramik zu Metall wird ein allmählicher Abbau der durch die unterschiedliche Wärmeausdehnung der beiden Werkstoffe im Bauteil hervorgerufenen Spannungen erreicht.The present invention relates to a method according to the preamble of claim 1. In her unpublished German patent application P 37 05 903.3, the applicant has described a method by means of which castings made of metallic material can be provided with a cast-in smooth lining, for. B. so-called portliner of internal combustion engines. Here layers are applied successively to a lost core by means of flame or plasma spraying, the composition of which is varied in such a way that a purely ceramic composition gradually becomes a finally purely metallic composition. An arbitrarily thick layer of metal can be cast onto the latter to complete the component. The graded transition from ceramic to metal leads to a gradual reduction of the stresses caused by the different thermal expansion of the two materials in the component.

Aufgabe der vorliegenden Erfindung ist eine Alternativlösung für das gleiche technische Problem, nämlich eine Beschichtung von metallischen Bauteilen, vorzugsweise auf der Innenseite solcher Bauteile, die hohl sind.The object of the present invention is an alternative solution to the same technical problem, namely a coating of metallic components, preferably on the inside of those components that are hollow.

Die Lösung dieser Aufgabe erfolgt durch die im kennzeichnenden Teil des 1. Anspruchs angegebenen Verfahrensschritte. Die erste Keramikschicht bildet im wesentlichen die gewünschte thermische Schutzschicht und ist mit Rücksicht hierauf in ihrer Dicke und Porosität zu bemessen; Schichten (die auf mehrere, herkömmliche Verfahrensweisen hergestellt werden können) von 2 bis 3 mm Dicke (ggf. aus mehreren, hintereinander aufgebrachten Teilschichten zusammengesetzt) erscheinen geeignet. Die Gleitschicht ihrerseits braucht nur eine Dicke von 0,05 bis 0,1 mm aufzuweisen und bewirkt vermöge ihrer Duktilität (die bei diesen geringen Dicken auch bei Verwendung von Metall gegeben ist) einen Abbau von Spannungen durch ein Aneinanderabgleiten der beiden Keramikschichten. Für die zweite Keramikschicht empfiehlt sich eine Schichtdicke von 0,1 bis 1 mm. Das Aufteilen derselben auf zahlreiche Segmente, die durch Fugen von wenigen Hundertstel mm voneinander getrennt sind, bietet eine Möglichkeit, die nach dem Umgießen der Schicht mit dem Metall durch dessen größere Wärmekontraktion bei der Abkühlung auftretenden Spannungen durch ein Schließen dieser Fugen zu verringern. Bei späterer erneuter Temperaturerhöhung im Betrieb folgt die zweite Keramikschicht durch erneutes Öffnen derselben.This object is achieved by the process steps specified in the characterizing part of claim 1. The first ceramic layer essentially forms the desired thermal protective layer and must be dimensioned with regard to its thickness and porosity; Layers (which can be produced by several conventional methods) of 2 to 3 mm thickness (if necessary from several, applied in succession Partial layers put together) appear suitable. The sliding layer in turn only needs to have a thickness of 0.05 to 0.1 mm and, due to its ductility (which is also the case with the use of metal at these small thicknesses), reduces stresses by sliding the two ceramic layers against one another. A layer thickness of 0.1 to 1 mm is recommended for the second ceramic layer. Splitting the same into numerous segments separated by joints of a few hundredths of a millimeter offers a possibility of reducing the stresses that occur after the coating of the metal has been cast around it by its greater thermal contraction during cooling by closing these joints. If the temperature rises again during operation, the second ceramic layer follows by opening it again.

Der 2. Anspruch lehrt ein Verfahren, wie die geforderten Fugen in definierter Größe und Häufigkeit hergestellt werden können. Verschiedene Kunststoffe erscheinen für die Herstellung des Gitters geeignet.The second claim teaches a method of how the required joints can be made in a defined size and frequency. Various plastics appear suitable for the production of the grid.

Bevorzugte Werkstoffe für die Herstellung der ersten Keramikschicht werden durch den 3. Anspruch bezeichnet. Sie weisen ebenso wie die weiter unten für die zweite Keramikschicht vorgeschlagenen Werkstoffe einen geringen E-Modul auf, wodurch die Übertragung von Vibrationen auf die Metallteile gedämpft wird.Preferred materials for the production of the first ceramic layer are designated by the third claim. Like the materials proposed below for the second ceramic layer, they have a low modulus of elasticity, which dampens the transmission of vibrations to the metal parts.

Der 4., 5. und 6. Anspruch lehrten alternative Werkstoffe, die für die Herstellung der Gleitschicht geeignet sind.The 4th, 5th and 6th claim taught alternative materials that are suitable for the production of the sliding layer.

Für die Bildung der zweiten Keramikschicht geeignete Werkstoffe werden schließlich im 7. Anspruch vorgeschlagen, die die geforderte Temperaturwechselfestigkeit bei guten mechanischen Eigenschaften und ausreichender chemischer Beständigkeit aufweisen.Materials suitable for the formation of the second ceramic layer are finally proposed in claim 7, which have the required resistance to temperature changes with good mechanical properties and sufficient chemical resistance.

Die im 8. Anspruch für die Herstellung der Keramikschichten und im 9. Anspruch für die Herstellung der Gleitschicht vorgeschlagenen, eng verwandten Verfahren eignen sich besonders zur Herstellung dünner, gleichmäßiger Schichten auf kompliziert geformten Oberflächen. An ihrer freien Oberfläche weisen sie eine gewisse Rauhigkeit auf, die der besseren Verzahnung der einzelnen Schichten untereinander dienlich ist.The closely related methods proposed in claim 8 for the production of the ceramic layers and in claim 9 for the production of the sliding layer are particularly suitable for the production of thin, uniform layers on complexly shaped surfaces. They have a certain roughness on their free surface, which is conducive to better interlinking of the individual layers.

Das erfindungsgemäße Verfahren erscheint besonders geeignet, das Innere von Hohlkörpern mit keramischen Schutzschichten zu versehen. Dazu empfiehlt sich die im 10. Anspruch vorgeschlagene Verwendung verlorener Kerne, von denen ausgehend das Bauteil aufgebaut wird. Wird entsprechend dem 11. Anspruch verfahren, kann eine sehr glatte Innenoberfläche des beschichteten Bauteils erzielt werden. Bei Verwendung niedrig­schmelzender Metalle kann das Glas durch einen geeigneten Kunststoff ersetzt werden.The method according to the invention appears particularly suitable for providing the inside of hollow bodies with ceramic protective layers. For this purpose, the use of lost cores, from which the component is built, is recommended. If the procedure according to claim 11 is followed, a very smooth inner surface of the coated component can be achieved. If low-melting metals are used, the glass can be replaced with a suitable plastic.

Ein Ausführungsbeispiel der Erfindung ist in der Zeichnung dargestellt, und zwar im Längsschnitt am Beispiel des Abgaskrümmers einer Verbrennungskraftmaschine. Die Dicken der einzelnen Schichten sind der Darstellbarkeit zuliebe stark übertrieben. Auf einen verlorenen Kern 1 aus Glas wurde mittels Plasma- oder Flammspritzen eine mehrere Millimeter dicke erste Keramikschicht 2 aufgebracht, auf diese dann eine sehr dünne Gleitschicht 3 aus Metall, Bornitrid oder Molybdändisulfid und auf diese wiederum nach dem gleichen Verfahren eine zweite Keramikschicht 4. Diese wird durch dünne Fugen 5 in einzelne Felder geteilt; dabei stellen die Fugen 5 die durch das Verbrennen eines vorher ihre Stelle einnehmenden Gitters hinterlassenen Lücken dar. Durch ein Umgießen des so hergestellten Gebildes mit einem den eigentlichen Körper des Bauteils bildenden Metall 6, z. B. Aluminium- oder Eisenguß und anschließende Zerstörung des Kernes 1 wird das Bauteil fertiggestellt.An embodiment of the invention is shown in the drawing, namely in longitudinal section using the example of the exhaust manifold of an internal combustion engine. The thicknesses of the individual layers are greatly exaggerated for the sake of representability. A lost ceramic core 1 was applied by means of plasma or flame spraying a first ceramic layer 2 several millimeters thick, then a very thin sliding layer 3 made of metal, boron nitride or molybdenum disulphide and a second ceramic layer 4 on this in turn by the same method is divided into individual fields by thin joints 5; the joints 5 represent the gaps left by the burning of a lattice that previously took their place. B. cast aluminum or iron and subsequent destruction of the core 1, the component is completed.

Claims (11)

1. Verfahren zur Herstellung eines mit einer Keramikauskleidung versehenen metallischen Bauteils in einer Form (1), wobei auf diese eine erste Keramikschicht (2) aufgebracht wird, gekennzeichnet durch folgende Schritte: a) Aufbringen einer Gleitschicht (3) auf die erste Keramik­schicht (2), b) Aufbringen einer zweiten, durch Fugen (5) in einzelne Bereiche geteilten Keramikschicht (4), c) in an sich bekannter Weise Umgießen der zweiten Keramik­schicht (4) mit Metall (6) zum fertigen Bauteil. 1. A method for producing a metallic component provided with a ceramic lining in a mold (1), a first ceramic layer (2) being applied to the latter, characterized by the following steps: a) applying a sliding layer (3) to the first ceramic layer (2), b) applying a second ceramic layer (4) divided into individual areas by joints (5), c) casting the second ceramic layer (4) with metal (6) into the finished component in a manner known per se. 2. Verfahren nach Anspruch 1,dadurch gekennzeichnet, daß die Fugen (5) in der zweiten Keramikschicht (4) durch ein auf die Gleitschicht (3) aufgelegtes Gitter aus einem Werkstoff vorgegeben werden, der durch den Vorgang des Aufbringens der Schicht und/oder durch das Umgießen verbrannt oder sublimiert wird.2. The method according to claim 1, characterized in that the joints (5) in the second ceramic layer (4) by a on the sliding layer (3) laid out grid made of a material which are determined by the process of applying the layer and / or is burned or sublimated by the casting. 3. Verfahren nach Anspruch 1,dadurch gekennzeichnet, daß die erste Keramikschicht (2) aus Aluminium-Titan-Oxyd, Magnesium-Aluminium-Silikat, Zirkonsilikat oder Mullit hergestellt wird.3. The method according to claim 1, characterized in that the first ceramic layer (2) made of aluminum-titanium oxide, magnesium-aluminum-silicate, zirconium silicate or mullite. 4. Verfahren nach Anspruch 1,dadurch gekennzeichnet, daß die Gleitschicht (3) aus einem Metall hergestellt wird.4. The method according to claim 1, characterized in that the sliding layer (3) is made of a metal. 5. Verfahren nach Anspruch 4,dadurch gekennzeichnet, daß die Gleitschicht (3) aus Titan oder aus einer Nickel-Aluminium-, Nickel-Chrom-, Nickel-Chrom-Aluminium-Yttrium-, Nickel-Kobalt-Chrom-Aluminium-­Yttrium- oder Kobalt-Chrom-Aluminium-Yttrium-Legierung hergestellt wird.5. The method according to claim 4, characterized in that the sliding layer (3) made of titanium or of a nickel-aluminum, nickel-chrome, nickel-chrome-aluminum-yttrium, nickel-cobalt-chrome-aluminum-yttrium- or cobalt-chrome-aluminum-yttrium alloy. 6. Verfahren nach Anspruch 1,dadurch gekennzeichnet, daß die Gleitschicht (3) aus Molybdändisulfid oder Bornitrid besteht.6. The method according to claim 1, characterized in that the sliding layer (3) consists of molybdenum disulfide or boron nitride. 7. Verfahren nach Anspruch 1,dadurch gekennzeichnet, daß die zweite Keramikschicht (4) aus Aluminiumtitanoxyd, Zirkonoxyd/Magnesiumoxyd, Zirkonoxyd/Yttriumoxyd, Zirkonsiliziumoxyd, Magnesium-Aluminium-Silikat, Aluminiumoxyd/Siliziumoxyd, Quarzgut, Mullit oder Spinell hergestellt wird.7. The method according to claim 1, characterized in that the second ceramic layer (4) made of aluminum titanium oxide, zirconium oxide / magnesium oxide, zirconium oxide / yttrium oxide, zirconium silicon oxide, magnesium aluminum silicate, aluminum oxide / silicon oxide, quartz material, mullite or spinel. 8. Verfahren nach Anspruch 1,dadurch gekennzeichnet, daß die erste und zweite Keramikschicht (2, 4) durch Plasma- oder Flammspritzen aufgetragen werden.8. The method according to claim 1, characterized in that the first and second ceramic layers (2, 4) are applied by plasma or flame spraying. 9. Verfahren nach Anspruch 1,dadurch gekennzeichnet, daß die Gleitschicht (3) durch Plasma- oder Flammspritzen aufgetragen wird.9. The method according to claim 1, characterized in that the sliding layer (3) is applied by plasma or flame spraying. 10. Verfahren nach Anspruch 1 zur Herstellung eines auf seiner Innenseite mit einer Keramikauskleidung (2, 4) versehenen hohlen Bauteils (6),dadurch gekennzeichnet, daß als Form ein verlorener Kern (1) verwendet wird.10. The method according to claim 1 for producing a on its inside with a ceramic lining (2, 4) provided hollow component (6), characterized in that a lost core (1) is used as the shape. 11. Verfahren nach Anspruch 10,dadurch gekennzeichnet, daß ein Kern (1) aus Glas verwendet wird.11. The method according to claim 10, characterized in that a core (1) made of glass is used.
EP88107493A 1987-05-21 1988-05-09 Method for manufacture of a ceramic coated metallic component Expired - Lifetime EP0292777B1 (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
AT88107493T ATE55565T1 (en) 1987-05-21 1988-05-09 PROCESS FOR MANUFACTURING A CERAMIC-COATED METALLIC COMPONENT.

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
DE3717152 1987-05-21
DE3717152 1987-05-21

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EP0292777A1 true EP0292777A1 (en) 1988-11-30
EP0292777B1 EP0292777B1 (en) 1990-08-16

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US (1) US4890663A (en)
EP (1) EP0292777B1 (en)
JP (1) JPS63303674A (en)
AT (1) ATE55565T1 (en)
DE (1) DE3860455D1 (en)

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PATENT ABSTRACTS OF JAPAN, Band 8, Nr. 227 (M-332)[1664], 18. Oktober 1984; & JP-A-59 108 848 (NISSAN JIDOSHA K.K.) 23-06-1984 *

Cited By (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE3940946A1 (en) * 1989-12-12 1990-11-08 Bayerische Motoren Werke Ag Cylinder head for IC engine - is made of one-piece light alloy casting with inlet and exhaust manifolds
EP0440093A1 (en) * 1990-01-26 1991-08-07 Isuzu Motors Limited Cast product having ceramics as insert and method of making same
WO1992009388A1 (en) * 1990-12-03 1992-06-11 Caterpillar Inc. Composite ceramic and metal article
WO1993024672A1 (en) * 1992-05-29 1993-12-09 United Technologies Corporation Ceramic thermal barrier coating for rapid thermal cycling applications
US5404721A (en) * 1994-01-28 1995-04-11 Ford Motor Company Cast-in-place ceramic manifold and method of manufacturing same

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DE3860455D1 (en) 1990-09-20
ATE55565T1 (en) 1990-09-15
US4890663A (en) 1990-01-02
EP0292777B1 (en) 1990-08-16
JPS63303674A (en) 1988-12-12

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