EP0773351A1 - Verfahren zur Herstellung eines Zylinderkopfes mit zweiteiliger Ventilsitzungen - Google Patents

Verfahren zur Herstellung eines Zylinderkopfes mit zweiteiliger Ventilsitzungen Download PDF

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Publication number
EP0773351A1
EP0773351A1 EP96114721A EP96114721A EP0773351A1 EP 0773351 A1 EP0773351 A1 EP 0773351A1 EP 96114721 A EP96114721 A EP 96114721A EP 96114721 A EP96114721 A EP 96114721A EP 0773351 A1 EP0773351 A1 EP 0773351A1
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EP
European Patent Office
Prior art keywords
valve seat
cylinder head
seat member
intake
outer circumferential
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.)
Granted
Application number
EP96114721A
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English (en)
French (fr)
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EP0773351B1 (de
Inventor
Junichi Inami
Shuhei Adachi
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.)
Yamaha Motor Co Ltd
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Yamaha Motor Co Ltd
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Filing date
Publication date
Application filed by Yamaha Motor Co Ltd filed Critical Yamaha Motor Co Ltd
Publication of EP0773351A1 publication Critical patent/EP0773351A1/de
Application granted granted Critical
Publication of EP0773351B1 publication Critical patent/EP0773351B1/de
Anticipated expiration legal-status Critical
Expired - Lifetime legal-status Critical Current

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    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01L—CYCLICALLY OPERATING VALVES FOR MACHINES OR ENGINES
    • F01L3/00—Lift-valve, i.e. cut-off apparatus with closure members having at least a component of their opening and closing motion perpendicular to the closing faces; Parts or accessories thereof
    • F01L3/22—Valve-seats not provided for in preceding subgroups of this group; Fixing of valve-seats

Definitions

  • This invention relates to a method for producing a cylinder head unit of an internal combustion engine, said cylinder head unit comprising a cylinder head body, an air intake system communicating with a combustion chamber at an at least one intake port opening, an exhaust system communicating with the combustion chamber at an at least one exhaust port opening, said intake and exhaust port openings are each operable by respective intake and exhaust valves guided by respective valve guides accommodated in respective valve guide holes, whereby a valve seat made of a material different from that of the cylinder head body is bonded to each of the respective intake and exhaust port openings, and to a valve seat member for a valve seat of an internal combustion engine having a cylinder head unit comprising a cylinder head body, an air intake system communicating with a combustion chamber at an at least one intake port opening, an exhaust system communicating with the combustion chamber at an at least one exhaust port opening, said intake and exhaust port openings are each operable by respective intake and exhaust valves guided by respective valve guides accommodated in respective valve guide holes.
  • the engine cylinder is constituted with a cylinder block and a cylinder head made of aluminum alloy.
  • the combustion chamber is formed between the cylinder head and a piston reciprocating within the cylinder block.
  • the cylinder head is constituted with a cylinder head body (made of aluminum alloy) and formed with intake and exhaust ports connected to the combustion chamber and valve seats attached to the combustion chamber side openings of those ports.
  • the valve seats are attached to parts contacted with the valve faces of the intake and exhaust valves.
  • the valve seats are made of iron-based sintered alloy excellent in wear resistance and high temperature strength because the valve seats are repeatedly contacted with the intake and exhaust valves and subjected to high temperatures.
  • press fit As a method of attaching the valve seats to the cylinder head body, press fit has been conventionally employed.
  • the press fit method has potential problems; difference in thermal conductivity between different metals and minute gaps present between them decrease thermal conductivity when heat is transmitted to the cylinder head, abnormal combustion occurs as a result of insufficient cooling of the cylinder head body, and valves are overheated.
  • a laser cladding method has been proposed (for example a Japanese laid-open patent publication No.
  • valve seat material which is excellent in heat resistance, wear resistance, and corrosion resistance is melted with laser beam and deposited (cladded) to part of the cylinder head body where the valve seat is to be attached, and the cladded layer is machined to form the valve seat.
  • the laser cladding method has also drawbacks; the material on the cylinder head body side is also melted when the metallic powder of the valve seat material is melted and material defects are produced such as blow holes due to gas produced, shrinkage pores due to solidification, loss of strength improving treatment applied to the cylinder head, decrease in bond strength, and deformation.
  • the inventors have considered a technique in which a valve seat member made of iron-based sintered alloy is bonded under heat and pressure.
  • the cylinder head body of aluminum alloy is heated by electric current application to cause plastic flow while the valve seat member is heated, pressed and sunk into the cylinder head body.
  • atoms on the boundary surface between both components diffuse mutually and both components are firmly bonded together without gaps.
  • FIG. 16 shows the method with an enlarged cross section of part of a cylinder head body (1) and a valve seat member (2).
  • the valve seat member (2) is set to a valve seat seating surface (3) as shown with broken lines. After the valve seat member (2) is sunk in the cylinder head body (1), excess portion is ground and finished.
  • FIG. 16 also shows the predetermined sinking depth range of the valve seat member (2). With this method, the valve seat member (2) and the cylinder head body (1) little melt. As a result, no material defects are produced, thermal conductivity is retained favorably, and a cylinder head free from thermal influence is obtained.
  • the amount of sinking the valve seat member (2) into the cylinder head body (1) varies and when the amount exceeds a preset range, problems occur. That is to say, as shown in FIG. 17(a), when the sinking amount of the valve seat member (2) is small, the valve seat member (2) might separate because the press contact surface is small and the bond strength is low.
  • the sinking amount of the valve seat member (2) is too great as shown in FIG. 17(b), material in the portion (G) is lost, a gap is produced between the valve seat and the valve face, and the valve function is impaired.
  • the valve seat member (2) is set as shown in FIGs.
  • the contact surface area varies. It will be easily appreciated that the variation in the contact surface area causes variation in the amount of heat generated by electric resistance during press contact, which in turn causes variation in the sinking amount.
  • the valve seat member (2) shown in FIG. 19(a) has an outer circumferential surface (2a) sloping down toward its center and a bottom surface (2b) continuing from the outer circumferential surface (2a) and sloping with a milder gradient than that of the outer circumferential surface.
  • the nearby portion H tends to melt easily. Therefore, after the valve seat member (2) is sunk and machined by grinding, the nearby portion remains as a melt layer in the interface between the valve seat and the cylinder head body (1), whereby the valve seat separation is apt to happen.
  • this objective is solved for a method in that said respective valve seat is provided by metallurgically bonding a respective valve seat member onto a valve seat seating surface of the respective intake and exhaust port openings, whereby an annular projection consisting of two surfaces and projecting from the inner circumferential side of the valve seat seating surface of the respective opening is formed, and the valve seat member has an outer circumferential surface sloping towards its center and a bottom surface continuing from the outer circumferential surface and sloping with a smaller gradient than that of the outer circumferential surface towards the center of said openings, whereby said bottom surface is in line-contact with said projection when said valve seat member is set onto said respective valve seat seating surface.
  • valve seat member in that said valve seat member consisting of a metal or a metal alloy being capable of forming an eutectic alloy with that cylinder head unit and comprising an outer circumferential surface sloping towards its center and a bottom surface continuing from the outer circumferential surface and sloping with a smaller gradient than that of the outer circumferential surface in a direction away from said outer circumferential surface, whereby said bottom surface is configured such that it is capable to come into line-contact with a projection projecting from the inner circumferential side of a valve seat seating surface of the respective intake or exhaust port opening of the cylinder head unit.
  • said valve seat surface comprises a flat plane transverse to the axis of the respective opening, first and second inside tapered surfaces continuing to the respective opening and an outside tapered surface continuing to the combustion chamber.
  • the cross-section of said annular valve seat member is defined by the outer circumferential surface, the bottom surface, an inner circumferential surface and a top surface.
  • the inner circumferential surface is formed by a slant surface approximately parallel to the outside tapered surface of the valve seat seating surface, and an axial surface extending axially from the inner circumferential side edge of said slant surface, and that the top surface connects the outer circumferential surface and the slant surface and being approximately parallel to the flat plane of the valve seat seating surface.
  • the pattern for the pressing force may comprise the first pushing force being applied at an early stage of the bonding process and then a second pushing force being applied with a certain higher value till bonding is completed.
  • the pattern of the applied electricity or current starts after a time has lapsed after the application of the first pushing force, whereby a first electric current is applied for a first time period followed by a first rest period with decreasing electric current, next a second electric current is applied for a second time period followed by a second rest period with decreasing electric current and finally a third electric current is applied for a third time period.
  • FIG. 1 is a partial sectional view of a cylinder head according to the invention
  • FIG. 2 is a view taken in the direction of the arrow II of FIG. 1
  • FIG. 3 is a sectional view showing a valve seat member being set on a valve seat seating surface, depicting only a part of the cylinder head body and the valve seat member on an enlarged scale.
  • numeral (11) designates a cylinder head body of a four-stroke, four-valve OHC type engine.
  • the cylinder head body (11) is made by casting with Al alloy.
  • the cylinder head body (11) is formed with a recess (12), facing downward, for defining a combustion chamber, together with a piston (not shown) reciprocating in a cylinder block, and on either side of the recess (12) is formed with two intake ports (13) and two exhaust ports (14), both ports having openings at the recess (12).
  • the cylinder head body 11 is shown with the bottom (the surface at which the recess 12 is open) upward in FIG. 3.
  • the Al alloy the material of the cylinder head body (11), is Al-Si-Mg-based A1 alloy specified as AC4C, AC4B or AC2B in JIS standard.
  • the reason why this material is adopted is that the valve seat can be bonded more firmly in this material than in any other Al alloy.
  • FIG. 1 in the upper wall portions of the intake and exhaust ports (13), (14) are mounted intake and exhaust valves (17), (18) through valve guides (15), (16), respectively.
  • the valve guides (15), (16) are press-fit in valve guide holes (11a) formed in the cylinder head body (11).
  • the valve guide holes (11a) are formed, with their axes C coinciding with the axes of the openings (13a), (14a).
  • numeral 8 in FIG. 2 designates a plug mounting hole.
  • the valve seat (19) shown in FIG. 1 is a seat in which an annular valve seat member (20) is bonded under heat and pressure to the valve seat seating surface (40) and finished by machining.
  • the valve seat seating surface (40) consists of a flat plane (41) perpendicular to the axis of the opening (13a) or (14a), first and second inside tapered surfaces (42), (43) continuing to the port (13) or (14), and an outside tapered surface (44) continuing to the recess 12.
  • Two surfaces, the flat plane (41) and the first inside tapered surface (42), forms an annular projection (46) projecting on the inner circumferential side of the opening (13a) or (14a) and having an apex of an obtuse angle.
  • the valve seat member (20 as shown in FIG. 3, consists of an annular body (21) made of Fe-based sintered alloy covered with a Cu film (22).
  • the alloy infiltrated with Cu is adopted for the purpose of avoiding development of internal resistance heat during energization as described later.
  • the film (22) is formed by electroplating the annular body (21) so as to be 0.1-30 ⁇ m in thickness.
  • the valve seat member (20) is of an annular shape as a whole, but its axial cross section is defined by an outer circumferential surface (50), a bottom surface (51), an inner circumferential surface 52, and a top surface (53).
  • the outer circumferential surface (50), as shown in FIG. 3, slopes down toward the center of the valve seat member, and the bottom surface (51) continues from the outer circumferential surface (50) and slopes with a milder gradient than that of the outer circumferential surface (50).
  • the inner circumferential surface (52) is formed by a slant surface (52a) approximately parallel with an outside tapered surface (44) of the valve seat seating surface (40), and an axial surface (52b) extending axially from the inner circumferential side edge of the slant surface (52a).
  • the top surface (53) connects the outer circumferential surface (50) and the slant surface (52a), and is formed so as to be approximately parallel with the flat plane (41) of the valve seat seating surface (40).
  • the bottom surface (51) comes into contact with the apex (45) of the annular projection, and the larger diameter side end portion projects into the recess (12); further, the angle ⁇ between the outside tapered surface (44) of the valve seat seating surface (40) and the outer circumferential surface (50), and the angle ⁇ between the first inside tapered surface (42) of the valve seat seating surface (40) and the bottom surface (51), are set so as to satisfy the relation ⁇ ⁇ ⁇ .
  • a pressure device (24) shown in FIG. 5 to FIG. 7 is used for bonding the valve seat members (20) to the valve seat seating surfaces (40) of the cylinder head body 11.
  • This pressure device (24) has a lower platen (26) fixed to the lower portion of a base frame (25), and an upper platen (27) is disposed upwardly of the lower platen (26) for vertical movement so as to be able to come into contact with the lower platen (26).
  • the upper platen (27) is fixed to the lower end of a rod (28a) which is the end portion of a cylinder device (28) mounted to the upper portion of the base frame vertically.
  • the upper and lower platens (26), (27) are supplied with electricity from a power supply (not shown) through conductors (26a), (27a).
  • the conductor (27a) connected to the upper platen (27) is adapted to be bent or moved vertically in response to the vertical movement of the upper platen (27).
  • the upper platen acts as an anode and the lower platen as a cathode.
  • a laser displacement meter (30) for measuring displacement of the upper platen (27) from the distance between the upper platen (27) and a reflection member (29) fixed to the front portion of the upper platen (27), using a laser beam being reflected by the reflection member (29).
  • valve seat member (20) To bond the valve seat member (20), first is fixed on the lower platen (26) an upper electrode (31), on which is mounted fixedly the cylinder head body (11). At this time, the cylinder head body (11) is positioned, with the recess (12) side upward and with the axis of the port opening, on which the valve seat member (20) is bonded, coinciding with the axis of a rod (28a) of the cylinder device (28).
  • a guide rod (32) is inserted from the recess (12) side into the valve guide hole (11a) of the port on which the valve seat member (20) is bonded.
  • the guide rod (32) is made of a metallic rod (32a) covered with insulating material such as alumina, and has a length such that it protrudes from the end face of the cylinder head body (11) on the combustion chamber side when inserted into the valve guide hole (11a) and held in place by a stopper (32c).
  • the insulating member (32b) is formed, in this embodiment, using a method in which ceramic material such as alumina is flame sprayed and then finished by polishing.
  • the valve seat member (20) on which is laid an upper electrode (33).
  • the upper electrode (33) is formed with a through hole (33a) for receiving said guide rod (32) at the axial center of its cylindrical metallic body, and at the lower end portion is formed with a tapered surface (33b) adapted to be in close contact with the slant surface (52a) (FIG.3) of the valve seat member (20) as well as a circumferential surface (33c) for positioning adapted to be in close contact with the axial surface (52b) over its entire circumference.
  • a magnetic body (33d) On the lower end portion of this upper electrode (33) is fixed a magnetic body (33d) for magnetically attracting the valve seat member (20).
  • the upper electrode (33) is positioned coaxially with the axis of the port opening of the cylinder head body (11), and when the tapered surface (33b) and the circumferential surface (33c) are brought into close contact with the valve seat member (20), the valve seat member (20) is also positioned coaxially with the port opening.
  • the upper electrode (33) is turned so as to receive a check whether the valve seat member (20) is fitted reliably.
  • the cylinder device (28) is operated and the upper platen (27) is moved downward so as to be brought into close contact with the upper electrode (33).
  • the bottom surface of the upper platen (27) and the top surface of the upper electrode (33) are adapted to be parallel to each other.
  • said cylinder device (28) is operated again to move the upper platen (27) downward, and the valve seat member (20) is pressed against the cylinder head body (11) with a certain pushing force.
  • valve seat member (20) Since the movement of the upper electrode (33) is restricted by the guide rod (32), the direction of the pushing force exerted on the valve seat member (20) coincides with the axis of the opening (13a) or (14a). Therefore, the valve seat member (20) is pressed coaxially with the opening (13a) or (14a).
  • the pushing force is changed according to the pushing force pattern shown in solid line in FIG. 8. That is, a first pushing force P1 of a certain lower value is applied at the early stage of the bonding process and then a second pushing force P2 of a certain higher value is applied till the downward movement is completed.
  • the distance between the laser displacement meter (30) and the reflection member (29) is measured by the displacement meter and recorded as a sinking movement starting point of the upper platen (27).
  • a voltage is applied between said upper and lower platens (27), (26) so as to allow an electric current to flow through the upper electrode (33), valve seat member (20), cylinder head body (11), and lower electrode (31).
  • the current flows from the upper electrode (33) toward the cylinder head body (11), and the current value is changed according to the current pattern shown in dash line in FIG. 8.
  • the applied current pattern is as follows: the first electric current I1 for a period t1, then a rest period r1, next the second electric current I2 larger than the first current I1 for a period t2, a rest period r2 again, finally the third current I3 larger than the second current I2 for a period t3, and while the second pushing force P2 is applied at the final stage of bonding, the electric current value is reduced to 0. That is, the current value is increased stepwise. Pressure conversion from the first pushing force P1 to the second pushing force P2 is performed during the time the second electric current I2 is applied and when a time t4 has elapsed after the electric current value was changed to the second current I2.
  • the applied electric current value (electric current density) is changable between the intake and exhaust port sides in such a manner that the current density on the exhaust port (14) side is larger (for example, by a factor of 1.1) than that on the intake port (13) side.
  • a specific example for the electric current values, period, and pushing force in FIG. 8 is given below.
  • the bottom surface (51) of the valve seat member (20) is in line-contact with the apex (45) of the annular projection of the cylinder head body (11) and the contact area between these two components is very small, so that when the electric current is applied, electric resistance becomes large enough to develop heat at the contact portion.
  • the resistance heat will be transmitted over the entire contact surface between the valve seat member (20) and the cylinder head body (11).
  • the crystalline structure near the interface turns to eutectic alloy between Cu in the film (22) and Al alloy in the cylinder head body (11), that is, into the state capable of changing from solid phase to liquid phase at lower temperature than pure Cu or Al alloy of the cylinder head body (11) does.
  • the state near the interface at this time is shown schematically in FIG. 9.
  • the portion where said eutectic alloy layer is produced as a result of the mutual atom diffusion, is designated by symbol A.
  • FIG. 10 shows the removed portion of the eutectic alloy in symbol B.
  • a part of the film (22) of the valve seat member (20) is turned into eutectic alloy and removed from the contact portion, therefore a part of the annular body (21) comes into contact with the Al alloy, which brings about the atom diffusion phenomena between these materials.
  • the portion developing atom diffusion is shown in symbol C in FIG. 10.
  • an unnecessary portion is removed from the cylinder head body (11) bonded with the valve seat member (20), for example, by grinding as shown in FIG. 12.
  • the finishing process removes the unnecessary portion of the annular body (21) together with the film (22), and the valve seat (19) bonded to the cylinder head body (11) through the atom diffusion area shown in symbol C in FIG. 11, is obtained.
  • the valve seat (19) now takes the form such that the dimensions A (length determining the projected area), B (maximum thickness), and ⁇ (angle between the outer circumferential surface and the machined surface) in FIG. 12 will satisfy the relations A ⁇ 2mm, B ⁇ 0.9mm, and ⁇ ⁇ 30 ° .
  • the valve seat member is set against the valve seat seating surface of the cylinder head body in line-contact relation. Therefore, when the valve seat member is bonded to the cylinder head body under heat and pressure, the amount of heat development becomes constant and the variation of the sinking amount is controlled within a specified range so that the thickness is always maintained at a preset value and adequate bond strength can be obtained without the possibility of separation.
  • the electric current does not concentrate on the outer circumferential side of the valve seat at the time of bonding, and the magnitude of the electric current flowing from the bottom surface side to the cylinder head body is increased. Therefore, the electric current density becomes high at the portion facing the bottom surface, which increases the possibility of melting; the melt layer is removed outside the interface without any residual owing to the valve seat member being pressed so that the valve seat separation due to the material defects will not happen.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • General Engineering & Computer Science (AREA)
  • Cylinder Crankcases Of Internal Combustion Engines (AREA)
EP19960114721 1995-09-14 1996-09-13 Verfahren zur Herstellung eines Zylinderkopfes mit zwei unterschiedlichen Ventilsitzen Expired - Lifetime EP0773351B1 (de)

Applications Claiming Priority (3)

Application Number Priority Date Filing Date Title
JP237264/95 1995-09-14
JP23726495A JPH0979012A (ja) 1995-09-14 1995-09-14 エンジン用シリンダヘッドの製造方法
JP23726495 1995-09-14

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EP0773351A1 true EP0773351A1 (de) 1997-05-14
EP0773351B1 EP0773351B1 (de) 2001-03-21

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EP19960114721 Expired - Lifetime EP0773351B1 (de) 1995-09-14 1996-09-13 Verfahren zur Herstellung eines Zylinderkopfes mit zwei unterschiedlichen Ventilsitzen

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JP (1) JPH0979012A (de)
DE (1) DE69612167T2 (de)

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
FR2773587A1 (fr) * 1998-01-15 1999-07-16 Renault Procede de fixation d'un siege de soupape sur la culasse d'un moteur

Families Citing this family (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20190091795A1 (en) * 2017-09-11 2019-03-28 Honda Motor Co., Ltd. Welded portion forming structure and metal member joining method

Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP0051300A1 (de) * 1980-10-31 1982-05-12 Nippon Kokan Kabushiki Kaisha Verfahren zur Herstellung eines Auslassventiles für einen Dieselmotor
JPS5877115A (ja) * 1981-10-31 1983-05-10 Nippon Piston Ring Co Ltd バルブシ−トの製造方法
EP0195177A2 (de) * 1985-03-18 1986-09-24 Tocco, Inc. Einrichtung zum induktiven Erhitzen von Ventilsitzen sowie Verfahren zur Anwendung der Einrichtung
EP0228282A2 (de) * 1985-12-25 1987-07-08 Toyota Jidosha Kabushiki Kaisha Aluminiumzylinderkopf mit einstückig geformtem Ventilsitz durch Kupferbeschichtung und Unterschicht

Patent Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP0051300A1 (de) * 1980-10-31 1982-05-12 Nippon Kokan Kabushiki Kaisha Verfahren zur Herstellung eines Auslassventiles für einen Dieselmotor
JPS5877115A (ja) * 1981-10-31 1983-05-10 Nippon Piston Ring Co Ltd バルブシ−トの製造方法
EP0195177A2 (de) * 1985-03-18 1986-09-24 Tocco, Inc. Einrichtung zum induktiven Erhitzen von Ventilsitzen sowie Verfahren zur Anwendung der Einrichtung
EP0228282A2 (de) * 1985-12-25 1987-07-08 Toyota Jidosha Kabushiki Kaisha Aluminiumzylinderkopf mit einstückig geformtem Ventilsitz durch Kupferbeschichtung und Unterschicht

Non-Patent Citations (1)

* Cited by examiner, † Cited by third party
Title
PATENT ABSTRACTS OF JAPAN vol. 007, no. 173 (M - 232) 30 July 1983 (1983-07-30) *

Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
FR2773587A1 (fr) * 1998-01-15 1999-07-16 Renault Procede de fixation d'un siege de soupape sur la culasse d'un moteur
EP0955452A1 (de) * 1998-01-15 1999-11-10 Renault Verfahren zum befestigen eines Ventilsitzes in einem Zylinderkopf

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JPH0979012A (ja) 1997-03-25
EP0773351B1 (de) 2001-03-21
DE69612167D1 (de) 2001-04-26
DE69612167T2 (de) 2001-07-19

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