EP0712340B1 - Casting process for producing a workpiece, in particular a piston, made of two different materials - Google Patents

Casting process for producing a workpiece, in particular a piston, made of two different materials Download PDF

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Publication number
EP0712340B1
EP0712340B1 EP94921574A EP94921574A EP0712340B1 EP 0712340 B1 EP0712340 B1 EP 0712340B1 EP 94921574 A EP94921574 A EP 94921574A EP 94921574 A EP94921574 A EP 94921574A EP 0712340 B1 EP0712340 B1 EP 0712340B1
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EP
European Patent Office
Prior art keywords
layer
alloy
piston
chrome
workpiece
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.)
Revoked
Application number
EP94921574A
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German (de)
French (fr)
Other versions
EP0712340A1 (en
Inventor
Ulrich Bischofberger
Dieter MÜLLER-SCHWELLING
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.)
Mahle GmbH
Original Assignee
Mahle GmbH
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Publication date
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Application filed by Mahle GmbH filed Critical Mahle GmbH
Publication of EP0712340A1 publication Critical patent/EP0712340A1/en
Application granted granted Critical
Publication of EP0712340B1 publication Critical patent/EP0712340B1/en
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    • 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
    • C23C6/00—Coating by casting molten material on the substrate
    • 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
    • B22D19/0027—Cylinders, pistons pistons
    • 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
    • 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

Definitions

  • the invention relates to a method for producing a component consisting of two different materials according to the preamble of claim 1.
  • EP-OS 0 353 480 discloses a method for introducing a local reinforcement, consisting of an iron-based material, into an aluminum piston.
  • the component to be introduced is first coated on the surfaces to be contacted with aluminum with a material consisting of particles which is also oxidation-resistant at higher temperatures.
  • the method used for this is usually a spraying method, with flame spraying, plasma spraying or arc spraying being possible.
  • the part is then preheated, placed in a mold and cast with an aluminum alloy.
  • Spray layers are not built up from a homogeneous material, but from many individual, initially molten and then quickly solidified particles.
  • Another disadvantage is the limitation of the layer materials, which according to the invention must also be resistant to oxidation even at higher temperatures, since otherwise oxide layers form during preheating, which lead to poor adhesion between the layer and the casting material.
  • the invention is therefore based on the problem of providing a part to be cast with a layer which is homogeneous, has no binding defects or internal defects, has good layer adhesion both with respect to iron or copper-based alloys and with aluminum-based alloys and thus to one uniformly high load capacity of the composite material.
  • the strength of the composite material according to the invention is said to far exceed the strength of the Alfin ring carrier binding, which has been known for around 40 years and is still in series production for the majority of pistons for diesel engines, since the ignition pressures of these pistons and thus the loads in the last Years have risen significantly.
  • the selection of the alloys for the immersion bath according to feature b) of the preamble is not limited to the Al alloys usually used in the Al-Fin process, but other immersion baths, preferably based on zinc or tin, can also be used.
  • the strength of the bond increases significantly compared to the alfine bond.
  • a Ni resist component (composition approx. 2.6% C / 2.1% Si / 1.2% Mn / 15% Ni / 1.3% Cr / 6% Cu, rest Fe) is first electroplated approximately 50 microns thick with chrome. The part is then approx. 3 min. immersed in an AlSi6 melt at 720 degrees Celsius, placed in the casting mold and immediately cast over when the immersion layer has not yet completely solidified.
  • the binding strength of samples produced in this way is 140-150 N / mm 2 .
  • the binding strength of appropriately produced samples without a chrome layer is only 50 - 60 N / mm 2 . If both processes are carried out on a component made of CuNi2Si, the bond strength is 140 - 150 N / mm 2 in the first process and 30 - 45 N / mm 2 in the second process.
  • connection is shown in the micrograph.
  • FIG. 1 shows the layer structure according to the invention in cross section: Between a previously defined NiResist material 1 and an AlSi material 4 there is a bonding layer made of electrodeposited chromium 2, which has a seam 3 made of intermetallic phases on the AlSi side.

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  • Engineering & Computer Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Mechanical Engineering (AREA)
  • Combustion & Propulsion (AREA)
  • General Engineering & Computer Science (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Materials Engineering (AREA)
  • Metallurgy (AREA)
  • Organic Chemistry (AREA)
  • Other Surface Treatments For Metallic Materials (AREA)
  • Coating By Spraying Or Casting (AREA)
  • Pistons, Piston Rings, And Cylinders (AREA)

Abstract

A casting process is disclosed for producing a workpiece, in particular a piston, made of two different materials. In order to solidly bind the base material and a second material, the piece to be cast is galvanically provided before casting with a chromium-containing layer and is then moulded by an Alfin process.

Description

Die Erfindung betrifft ein Verfahren zur Herstellung eines Bauteils, bestehend aus zwei unterschiedlichen Werkstoffen nach dem Oberbegriff des Anspruchs 1.The invention relates to a method for producing a component consisting of two different materials according to the preamble of claim 1.

Aus der EP-OS 0 353 480 ist ein Verfahren zum Einbringen einer lokalen Verstärkung , bestehend aus einem Eisenbasiswerkstoff, in einen Aluminiumkolben bekannt. Dabei wird das einzubringende Bauteil zunächst auf den mit Aluminium zu kontaktierenden Flächen mit einem auch bei höheren Temperaturen oxidationsbeständigen aus Partikeln bestehenden Material beschichtet.EP-OS 0 353 480 discloses a method for introducing a local reinforcement, consisting of an iron-based material, into an aluminum piston. The component to be introduced is first coated on the surfaces to be contacted with aluminum with a material consisting of particles which is also oxidation-resistant at higher temperatures.

Das hierzu eingesetzte Verfahren ist üblicherweise ein Spritzverfahren, wobei Flammspritzen, Plasmaspritzen oder Lichtbogenspritzen in Frage kommen.The method used for this is usually a spraying method, with flame spraying, plasma spraying or arc spraying being possible.

Anschließend wird das Teil vorgewärmt, in eine Gießform eingelegt und mit einer Aluminiumlegierung umgossen.The part is then preheated, placed in a mold and cast with an aluminum alloy.

Dieses Verfahren hat mehrere Nachteile:This procedure has several disadvantages:

Spritzschichten sind nicht aus einem homogenen Material aufgebaut, sondern aus vielen einzelnen, zunächst schmelzflüssigen und anschließend schnell erstarrten Partikeln.Spray layers are not built up from a homogeneous material, but from many individual, initially molten and then quickly solidified particles.

Poren und Bindefehler sowohl an der Grenzfläche als auch in der Schicht selbst können nie vollkommen ausgeschlossen werden. Die Beschichtung von Kanten und Ecken bereitet erhebliche Probleme. Definierte Schichtstärken mit Abstufungen im Bereich von wenigen Mymeter lassen sich nicht herstellen und es wird unter Umständen mehr Material als unbedingt notwendig aufgetragen.Pores and binding defects both at the interface and in the layer itself can never be completely ruled out. The coating of edges and corners creates considerable problems. Defined layer thicknesses with gradations in the range of a few meters cannot be produced and more material than is absolutely necessary may be applied.

Einen Hinweis auf die ungleichmäßige Ausbildung der Spritzschicht liefert schon die in obengenannter Schrift enthaltene Tabelle mit Festigkeitswerten, bei der selbst bei gleicher Schichtstärke Unterschiede von 26% in der Festigkeit gemessen wurden. Ein so hergestellter Verbundwerkstoff weist also lokal unterschiedliche Festigkeitswerte auf.An indication of the uneven formation of the spray layer is already provided in the table with strength values contained in the above-mentioned document, in which differences of 26% in strength were measured even with the same layer thickness. A composite material produced in this way therefore has locally different strength values.

Ein weiterer Nachteil liegt in der Beschränkung der Schichtwerkstoffe, die erfindungsgemäß auch bei höheren Temperaturen oxidationsbeständig sein müssen, da sich sonst beim Vorwärmen Oxidschichten bilden, die zu einer schlechten Haftung zwischen Schicht und Umgußmaterial führen.Another disadvantage is the limitation of the layer materials, which according to the invention must also be resistant to oxidation even at higher temperatures, since otherwise oxide layers form during preheating, which lead to poor adhesion between the layer and the casting material.

Der Erfindung liegt daher das Problem zugrunde, ein zu umgießendes Teil mit einer Schicht zu versehen, die homogen ist, keine Bindefehler oder inneren Fehler aufweist, eine gute Schichthaftung sowohl gegenüber Eisen- bzw. Kupfer-Basislegierungen als auch gegenüber Aluminiumbasislegierungen aufweist und somit zu einer gleichmäßig hohen Belastbarkeit des Werkstoffverbundes führt. Insbesondere soll die Festigkeit des erfindungsgemäßen Werkstoffverbundes die Festigkeit der seit ca. 40 Jahren bekannten und bis heute beim Großteil der Kolben für Dieselmotoren in Serie produzierten Alfin-Ringträger-Bindung weit überschreiten, da die Zünddrücke dieser Kolben und damit die Belastungen in den letzten Jahren erheblich gestiegen sind.The invention is therefore based on the problem of providing a part to be cast with a layer which is homogeneous, has no binding defects or internal defects, has good layer adhesion both with respect to iron or copper-based alloys and with aluminum-based alloys and thus to one uniformly high load capacity of the composite material. In particular, the strength of the composite material according to the invention is said to far exceed the strength of the Alfin ring carrier binding, which has been known for around 40 years and is still in series production for the majority of pistons for diesel engines, since the ignition pressures of these pistons and thus the loads in the last Years have risen significantly.

Eine Lösung dieses Problems zeigt das kennzeichnende Merkmal des Anspruchs 1 auf. Durch die galvanische Aufbringung einer Chromschicht auf das eisen- oder kupferhaltige Teil wird in Verbindung mit den weiteren Verfahrensschritten des Alfinverfahrens eine homogene und gut haftende Verbindung mit der Aluminiumbasislegierung geschaffen.A solution to this problem is shown in the characterizing feature of claim 1. The galvanic application of a chrome layer to the iron or copper-containing part in connection with the further process steps of the Alfin process creates a homogeneous and well-adhering connection with the aluminum-based alloy.

Dabei beschränkt sich die Auswahl der Legierungen für das Tauchbad nach Merkmal b) des Oberbegriffs nicht auf die üblicherweise beim Al-Fin-Verfahren verwendeten Al-Legierungen, sondern es können auch andere Tauchbäder, vorzugsweise auf Zink- oder Zinn-Basis eingesetzt werden.The selection of the alloys for the immersion bath according to feature b) of the preamble is not limited to the Al alloys usually used in the Al-Fin process, but other immersion baths, preferably based on zinc or tin, can also be used.

Die Festigkeit der Bindung nimmt, verglichen mit der Alfinbindung, stark zu.The strength of the bond increases significantly compared to the alfine bond.

Die Erfindung wird im folgenden anhand von zwei Ausführungsbeispielen näher erläutert: Ein Ni-Resist-Bauteil (Zusammensetzung ca. 2,6 % C / 2,1 % Si / 1,2 % Mn / 15 % Ni / 1,3 % Cr / 6 % Cu, Rest Fe) wird zunächst galvanisch ca. 50 Mymeter stark mit Chrom beschichtet. Das Teil wird anschließend ca. 3 min. bei 720 Grad Celsius in einer AlSi6-Schmelze getaucht, in die Gießform gelegt und sofort bei noch nicht vollständig erstarrter Tauchschicht umgossen. Die Bindungsfestigkeit von so hergestellten Proben liegt bei 140 - 150 N/mm2. Die Bindungsfestigkeit von entsprechend hergestellten Proben ohne Chromschicht liegt nur bei 50 - 60 N/mm2. Führt man beide Verfahren an einem Bauteil aus CuNi2Si durch, so liegt beim ersten Verfahren die Bindungsfestigkeit bei 140 - 150 N/mm2, beim zweiten Verfahren bei 30 - 45 N/mm2.The invention is explained in more detail below with reference to two exemplary embodiments: A Ni resist component (composition approx. 2.6% C / 2.1% Si / 1.2% Mn / 15% Ni / 1.3% Cr / 6% Cu, rest Fe) is first electroplated approximately 50 microns thick with chrome. The part is then approx. 3 min. immersed in an AlSi6 melt at 720 degrees Celsius, placed in the casting mold and immediately cast over when the immersion layer has not yet completely solidified. The binding strength of samples produced in this way is 140-150 N / mm 2 . The binding strength of appropriately produced samples without a chrome layer is only 50 - 60 N / mm 2 . If both processes are carried out on a component made of CuNi2Si, the bond strength is 140 - 150 N / mm 2 in the first process and 30 - 45 N / mm 2 in the second process.

Im Schliffbild ist die Verbindung dargestellt.The connection is shown in the micrograph.

Es zeigt Fig. 1 den erfindungsgemäßen Schichtaufbau im Querschliff:
   Zwischen einem vorstehend definierten NiResist-Werkstoff 1 und einem AlSi-Werkstoff 4 liegt eine Bindeschicht aus galvanisch abgeschiedenem Chrom 2, die auf der AlSi-Seite einen Saum 3 aus intermetallischen Phasen aufweist.1 shows the layer structure according to the invention in cross section:
Between a previously defined NiResist material 1 and an AlSi material 4 there is a bonding layer made of electrodeposited chromium 2, which has a seam 3 made of intermetallic phases on the AlSi side.

Claims (4)

  1. Casting process for producing a workpiece, in particular a piston, made of two different materials, of which one material is an alloy with an iron or copper base and the other is an alloy with an aluminium base, with the following process steps
    a) coating the iron or copper-containing part,
    b) immersing the iron or copper-containing part in a metal melt, preferably comprising an alloy with an aluminium, zinc or tin base,
    c) placing the part into a casting mould,
    d) casting around the part with an alloy with an aluminium base,
    characterised in that
    a chrome-containing layer is applied galvanically onto the part to be coated and said chrome-containing layer is only partially dissolved in further stages of the process and not completely dissolved.
  2. Process according to claim 1,
    characterised in that,
    the chrome content in the galvanically produced layer is at least 25 %.
  3. Process according to claim 1,
    characterised in that
    the chrome content in the galvanically produced layer is at least 50 %.
  4. Process according to claim 1,
    characterised in that
    the chrome content in the galvanically produced layer is at least 80 %.
EP94921574A 1993-08-02 1994-07-19 Casting process for producing a workpiece, in particular a piston, made of two different materials Revoked EP0712340B1 (en)

Applications Claiming Priority (3)

Application Number Priority Date Filing Date Title
DE19934325864 DE4325864A1 (en) 1993-08-02 1993-08-02 Casting process for producing a component, in particular a piston, consisting of two different materials
DE4325864 1993-08-02
PCT/DE1994/000830 WO1995003905A1 (en) 1993-08-02 1994-07-19 Casting process for producing a workpiece, in particular a piston, made of two different materials

Publications (2)

Publication Number Publication Date
EP0712340A1 EP0712340A1 (en) 1996-05-22
EP0712340B1 true EP0712340B1 (en) 1997-01-15

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ID=6494252

Family Applications (1)

Application Number Title Priority Date Filing Date
EP94921574A Revoked EP0712340B1 (en) 1993-08-02 1994-07-19 Casting process for producing a workpiece, in particular a piston, made of two different materials

Country Status (5)

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EP (1) EP0712340B1 (en)
JP (1) JPH09500831A (en)
BR (1) BR9406882A (en)
DE (2) DE4325864A1 (en)
WO (1) WO1995003905A1 (en)

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE102004013181B3 (en) * 2004-03-17 2005-09-22 Federal-Mogul Nürnberg GmbH Piston for an internal combustion engine, method of manufacturing a piston, and use of a copper alloy to make a piston

Families Citing this family (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE19537848A1 (en) * 1995-10-11 1997-04-17 Mahle Gmbh Reinforcement part, the base material of which is austenitic cast iron
DE10134293B4 (en) * 2001-07-14 2009-06-04 Mahle Gmbh Cooled ring carrier for a piston
DE10137436C2 (en) * 2001-07-31 2003-07-31 Ks Kolbenschmidt Gmbh Pre-finishing of cast parts
CN106435653B (en) * 2016-11-24 2018-09-04 昆明冶金研究院 A kind of Zinc electrolysis commercial bronze aluminium conductive transition part preparation method
CN106735098A (en) * 2016-12-12 2017-05-31 晋宁理工恒达科技有限公司 A kind of copper aluminium die casting compound polar plate conductive head and preparation method thereof
CN110788301B (en) * 2019-10-18 2022-03-15 郑州机械研究所有限公司 Method suitable for strengthening braze-coating modification on surface of copper-based bearing bush
CN110640114A (en) * 2019-10-31 2020-01-03 陕西航空电气有限责任公司 Method for overcoming defect of casting looseness of motor shell
DE102020100640A1 (en) 2020-01-14 2021-07-15 Stahlzentrum Freiberg e.V. Process for improving the corrosion resistance of fastening and / or reinforcement components made of high-alloy steels and fastening and / or reinforcement components made of high-alloy steels

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DE901104C (en) * 1949-11-10 1954-01-07 Fairchild Engine And Airplane Composite casting and process for its manufacture
DE1458426C3 (en) * 1964-04-17 1973-10-18 Koerver & Nehring Gmbh, 4150 Krefeld Austenitic cast iron with spheroidal graphite
AR204180A1 (en) * 1973-12-03 1975-11-28 Oxy Metal Industries Corp METHOD OF FORMING A CASE ESSENTIALLY COMPOSED OF ALUMINUM FOR THE RUNNING TRACK OF AN INTERNAL COMBUSTION ROTARY ENGINE
SE444032B (en) * 1984-06-01 1986-03-17 Kanthal Ab MAKE MANUFACTURING PISTON FOR COMBUSTION ENGINE
GB8818214D0 (en) * 1988-07-30 1988-09-01 T & N Technology Ltd Pistons
CA2024210A1 (en) * 1989-11-06 1991-05-07 William D. Guenther Method of treating a ferrous component for subsequent metallurgical bonding to cast aluminum
CH682307A5 (en) * 1991-02-05 1993-08-31 Alusuisse Lonza Services Ag
DE4125064A1 (en) * 1991-07-29 1993-02-04 Linde Ag BRAKE DISC

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE102004013181B3 (en) * 2004-03-17 2005-09-22 Federal-Mogul Nürnberg GmbH Piston for an internal combustion engine, method of manufacturing a piston, and use of a copper alloy to make a piston

Also Published As

Publication number Publication date
WO1995003905A1 (en) 1995-02-09
DE4325864A1 (en) 1995-05-11
EP0712340A1 (en) 1996-05-22
JPH09500831A (en) 1997-01-28
DE59401619D1 (en) 1997-02-27
BR9406882A (en) 1996-04-02

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