EP0790397B1 - Circuit liner unit for an internal combustion engine and method of fabrication - Google Patents

Circuit liner unit for an internal combustion engine and method of fabrication Download PDF

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Publication number
EP0790397B1
EP0790397B1 EP97100662A EP97100662A EP0790397B1 EP 0790397 B1 EP0790397 B1 EP 0790397B1 EP 97100662 A EP97100662 A EP 97100662A EP 97100662 A EP97100662 A EP 97100662A EP 0790397 B1 EP0790397 B1 EP 0790397B1
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EP
European Patent Office
Prior art keywords
cylinder liner
cylinder
layer
liner
mandrel
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
EP97100662A
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German (de)
French (fr)
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EP0790397A1 (en
Inventor
Peter Gödel
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Federal Mogul Burscheid GmbH
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Federal Mogul Burscheid GmbH
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Publication of EP0790397A1 publication Critical patent/EP0790397A1/en
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Classifications

    • 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
    • F02F1/00—Cylinders; Cylinder heads 
    • F02F1/18—Other cylinders
    • F02F1/20—Other cylinders characterised by constructional features providing for lubrication
    • 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
    • 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
    • B22D19/08—Casting in, on, or around objects which form part of the product for building-up linings or coverings, e.g. of anti-frictional metal
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D23/00—Casting processes not provided for in groups B22D1/00 - B22D21/00
    • B22D23/003—Moulding by spraying metal on a surface
    • 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
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00—Metal working
    • Y10T29/49—Method of mechanical manufacture
    • Y10T29/49229—Prime mover or fluid pump making
    • Y10T29/4927—Cylinder, cylinder head or engine valve sleeve making
    • Y10T29/49272—Cylinder, cylinder head or engine valve sleeve making with liner, coating, or sleeve

Definitions

  • the invention relates to a cylinder liner for internal combustion engines for use in the cylinder bores of an engine block, the cylinder liner being produced in a free-form process by thermal spraying of spray material onto a mandrel serving as a shaped body to form a cylinder wall, and the process for its production.
  • cylinder liners In internal combustion engines with an engine block made of cast iron or aluminum alloys, it is common practice to insert cylinder liners into the cylinder bores of the engine block.
  • the bushings consist of cylindrical tube sections and limit the combustion chamber of the combustion chamber with their inner surfaces in the engine, the inner surfaces simultaneously serving as running surfaces for the piston rings.
  • wear-resistant cast iron or steel alloys or sintered materials are used as the liner materials.
  • the running surfaces of the bushings must also be machined, and if necessary the running surfaces are provided with wear-resistant coatings.
  • cylinder liners can only be manufactured within a limited range of dimensions using the casting and sintering processes.
  • thin-walled cylinder liners which are required above all for modern car engines with engine blocks made of aluminum alloys to optimize performance, cannot be produced using the previous processes, or can be produced only with great effort.
  • US 5110631 A discloses a method for coating bodies by spraying on spray materials.
  • the spray material is sprayed onto the body in a special spraying technique and is used to produce separate bodies or as a coating.
  • the coating structure is one layer.
  • the present invention has for its object to provide a cylinder liner for internal combustion engines and a method of their manufacture, with which a cylinder liner can be manufactured easily and inexpensively with optimally thin walls and high wear resistance and can then be used as an independent component in an engine block ..
  • a dome with an outer circumference corresponding to the inner circumference of the cylinder liner to be produced is used as the molded body, and the spray material is applied in the desired thickness to the outer circumferential surface of the rotating mandrel by one of the known thermal spray processes. After removal from the mandrel, the bushing is machined on the end faces.
  • the completed cylinder liner according to the invention is stable and can be easily stored and handled from manufacture to installation in the engine block.
  • cylinder liners with standard diameters can be produced for all common engine types.
  • the socket can be manufactured primarily with thin walls with wall thicknesses of greater than or equal to 1 mm and in lengths from 100 mm to 260 mm. Other dimensions would also be conceivable.
  • the layer forming the tread consists of a particularly wear-resistant and fire-retardant material made of molybdenum or a molybdenum alloy, while the outer cover layer can consist of an aluminum alloy.
  • a bonding layer made of, for example, a self-flowing cobalt or nickel alloy can be applied in between. It is particularly advantageous here that the choice of material can be matched to the application and, above all, that a tread layer with optimal tribological properties can be produced by adjusting the spraying parameters.
  • the outer circumferential surface of the molded body is hard chrome-plated and optionally provided with a non-stick spray, so that the finished bushing can be easily removed from the molded body.
  • a special and complex machining of the tread of the bush is not necessary in most cases, since the tread has a shape corresponding to the surface of the molded body.
  • the cylinder liners according to the invention were tested in engine tests.
  • the cylinder liner was also optimally wear-resistant in endurance tests and ran trouble-free.
  • the invention thus creates a cylinder liner that can be produced simply and inexpensively by the method according to the invention.
  • the liner according to the invention can be manufactured with optimal wear resistance values and tribological properties.
  • the cylinder liner with thin-walled geometry can be manufactured for practically all engine types.
  • the invention is illustrated in the drawing using an exemplary embodiment.
  • the cylinder liner (1) is formed from three superimposed thermal spray layers.
  • the inner layer (2) of the cylinder liner consists of a wear-resistant and fire-proof molybdenum layer. It forms the running surface for the piston rings and limits the combustion chamber of the combustion chamber.
  • a low-melting cobalt alloy is applied as an intermediate adhesive layer (3) to the outer peripheral surface of the molybdenum layer (2), and the outer layer (4) of the cylinder liner (1) consists of an aluminum alloy as a cover layer.
  • the transitions between the individual layers (2, 3, 4) can be carried out in a graded manner.

Landscapes

  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Combustion & Propulsion (AREA)
  • General Engineering & Computer Science (AREA)
  • Coating By Spraying Or Casting (AREA)
  • Cylinder Crankcases Of Internal Combustion Engines (AREA)
  • Pistons, Piston Rings, And Cylinders (AREA)

Abstract

The cylinder liner (1) for insertion into the bore of a cylinder block consists of a wear resistant layer (2) thermally applied onto its inner circumference and a cover layer (4) applied onto its outer circumference. Also claimed is the manufacture of such a liner, comprising thermal spraying of material to produce a cylinder liner (1) for internal combustion engines. A first wear resistant layer (2) is sprayed onto the surface of a mandrel serving as a moulding element, a cover layer (4) is sprayed onto the layer (2), and the cylinder liner thus produced is drawn off the mandrel.

Description

Die Erfindung betrifft eine Zylinderlaufbuchse für Verbrennungskraftmaschinen zum Einsatz in die Zylinderbohrungen eines Motorblocks wobei die Zylinderlaufbuchse im Freiformverfahren durch thermisches Aufspritzen von Spritzmaterial auf einen als Formkörper dienenden Dorn unter Bildung einer Zylinderwandung hergestellt ist sowie das Verfahren ihrer Herstellung.The invention relates to a cylinder liner for internal combustion engines for use in the cylinder bores of an engine block, the cylinder liner being produced in a free-form process by thermal spraying of spray material onto a mandrel serving as a shaped body to form a cylinder wall, and the process for its production.

Bei Verbrennungskraftmaschinen mit einem Motorblock aus Gußeisen- oder Aluminiumlegierungen ist es vielfach üblich, in die Zylinderbohrungen des Motorblocks Zylinderlaufbuchsen einzusetzen. Die Buchsen bestehen aus zylindrischen Rohrabschnitten und begrenzen im Motor mit ihren Innenflächen den Brennraum der Verbrennungskammer, wobei die Innenflächen gleichzeitig als Laufflächen für die Kolbenringe dienen. Entsprechend der hohen Verschleißbelastung werden als Laufbuchsenwerkstoffe verschleißfeste Gußeisen- oder Stahllegierungen oder auch Sinterwerkstoffe verwendet. Die Laufflächen der Buchsen müssen zusätzlich aufwendig spanabhebend bearbeitet werden, und gegebenenfalls sind die Laufflächen mit verschleißfesten Beschichtungen versehen.In internal combustion engines with an engine block made of cast iron or aluminum alloys, it is common practice to insert cylinder liners into the cylinder bores of the engine block. The bushings consist of cylindrical tube sections and limit the combustion chamber of the combustion chamber with their inner surfaces in the engine, the inner surfaces simultaneously serving as running surfaces for the piston rings. Depending on the high wear, wear-resistant cast iron or steel alloys or sintered materials are used as the liner materials. The running surfaces of the bushings must also be machined, and if necessary the running surfaces are provided with wear-resistant coatings.

Die Herstellung solcher Zylinderlaufbuchsen ist in der Praxis dadurch aufwendig und kostspielig. Zusätzlich können im Gußverfahren und Sinterverfahren Zylinderlaufbuchsen nur innerhalb begrenzter Abmessungsbereiche hergestellt werden. Insbesondere dünnwandige Zylinderlaufbuchsen, die vor allem für moderne PKW-Motoren mit Motorblöcken aus Aluminiumlegierungen zur Leistungsoptimierung benötigt werden, können nach den bisherigen Verfahren nicht oder nur sehr aufwendig hergestellt werden.The production of such cylinder liners is therefore complex and expensive in practice. In addition, cylinder liners can only be manufactured within a limited range of dimensions using the casting and sintering processes. In particular, thin-walled cylinder liners, which are required above all for modern car engines with engine blocks made of aluminum alloys to optimize performance, cannot be produced using the previous processes, or can be produced only with great effort.

Aus der DE PS 1 282 243 ist ein Verfahren zum Herstellen von Aluminiumzylindern mit eingegossenen Stahllaufbuchsen zu entnehmen, wonach eine Stahlschicht auf einen Dorn gespritzt wird. Zur Verbindung der Laufbuchse mit dem Zylinder wird in der Laufbuchse ein Unterdruck erzeugt, so daß das Aluminium in die Poren der Umfangsfläche eindringt. Die Laufbuchse besteht aus nur einer Schicht.From DE PS 1 282 243 a method for producing aluminum cylinders with cast steel liners can be seen, according to which a steel layer on a Thorn is injected. To connect the cylinder liner to the cylinder, a negative pressure is generated in the cylinder liner so that the aluminum penetrates into the pores of the peripheral surface. The liner consists of only one layer.

Die US 5110631 A offenbart ein Verfahren zur Beschichtung von Körpern, durch aufspritzen von Spritzmaterialien. Das Spritzmaterial wird in einer besonderen Spritztechnik auf die Körper gesprtiz und dient zur Herstellung von separaten Körpern oder als Beschichtung. Der Beschichtungsaufbau ist einlagig.US 5110631 A discloses a method for coating bodies by spraying on spray materials. The spray material is sprayed onto the body in a special spraying technique and is used to produce separate bodies or as a coating. The coating structure is one layer.

Der vorliegenden Erfindung liegt die Aufgabe zugrunde, eine Zylinderlaufbuchse für Verbrennungsmaschinen und ein Verfahren ihrer Herstellung zu schaffen, mit dem eine Zylinderlaufbuchse bei hoher Verschleißfestigkeit einfach und kostengünstig mit optimal dünner Wandstärke hergestellt werden kann und anschließend als eigenständiges Bauteil in einem Motorblock einsetzbar ist..The present invention has for its object to provide a cylinder liner for internal combustion engines and a method of their manufacture, with which a cylinder liner can be manufactured easily and inexpensively with optimally thin walls and high wear resistance and can then be used as an independent component in an engine block ..

Erfindungsgemäß wird diese Aufgabe durch die kennzeichnenden Merkmale der Patentansprüche 1 und 3 gelöst.
Eine vorteilhafte Ausgestaltung ist im Unteranspruch dargelegt.According to the invention, this object is achieved by the characterizing features of claims 1 and 3.
An advantageous embodiment is set out in the subclaim.

Für das angewendeten Verfahren wird als Formkörper ein Dom mit einem dem Innenumfang der herzustellenden Zylinderlaufbüchse entsprechenden Außenumfang verwendet, und auf die äußere Umfangsfläche des rotierenden Dorns wird nach einem der bekannten thermischen Spritzverfahren das Spritzmaterial in der gewünschten Stärke aufgetragen. Nach dem Abziehen vom Dorn wird die Buchse an den Stirnflächen bearbeitet.For the process used, a dome with an outer circumference corresponding to the inner circumference of the cylinder liner to be produced is used as the molded body, and the spray material is applied in the desired thickness to the outer circumferential surface of the rotating mandrel by one of the known thermal spray processes. After removal from the mandrel, the bushing is machined on the end faces.

Die fertiggestellte erfindungsgemäße Zylinderlaufbuchse ist stabil und kann problemlos von der Herstellung bis zum Einbau in den Motorblock gelagert und gehandhabt werden. Nach dem erfindungsgemäßen Verfahren können Zylinderlaufbuchsen mit Normdurchmessern für alle gängigen Motorentypen hergestellt werden. Die Buchse kann vor allem dünnwandig mit Wandstärken von größer gleich 1 mm sowie in Längen von 100 mm bis 260 mm hergestellt werden. Denkbar wären auch andere Abmessungen.The completed cylinder liner according to the invention is stable and can be easily stored and handled from manufacture to installation in the engine block. According to the method according to the invention, cylinder liners with standard diameters can be produced for all common engine types. The socket can be manufactured primarily with thin walls with wall thicknesses of greater than or equal to 1 mm and in lengths from 100 mm to 260 mm. Other dimensions would also be conceivable.

Als thermische Spritzverfahren sind alle bekannten Spritzverfahren prinzipiell anwendbar. Bevorzugt wird aber das Flammspritzverfahren. Als Spritzmaterialien sind die im Handel erhältlichen Spritzwerkstoffe aus Metall und/oder Metallkeramik einsetzbar. Die die Lauffläche bildende Schicht besteht aus einem besonders verschleißfesten und brandspursicherem Material aus Molybdän oder einer Molybdänlegierung bestehen, während die äußere Deckschicht aus einer Aluminiumlegierung bestehen kann. Dazwischen kann eine Bindeschicht aus beispielsweise einer selbstfließenden Kobalt- oder Nickellegierung aufgetragen sein. Besonders vorteilhaft ist dabei, daß die Materialauswahl auf den Anwendungsfall abgestimmt sein kann und durch Einstellung der Spritzparameter vor allem eine Laufflächenschicht mit optimalen tribologischen Eigenschaften hergestellt werden kann.In principle, all known spray processes can be used as thermal spray processes. However, the flame spraying method is preferred. The spray materials made of metal and / or metal ceramics which are commercially available can be used as spray materials. The layer forming the tread consists of a particularly wear-resistant and fire-retardant material made of molybdenum or a molybdenum alloy, while the outer cover layer can consist of an aluminum alloy. A bonding layer made of, for example, a self-flowing cobalt or nickel alloy can be applied in between. It is particularly advantageous here that the choice of material can be matched to the application and, above all, that a tread layer with optimal tribological properties can be produced by adjusting the spraying parameters.

Die äußere Umfangsfläche des Formkörpers ist hartverchromt und gegebenenfalls mit einem Antihaftspray versehen, sodaß die fertiggestellte Buchse von dem Formkörper problemlos abgezogen werden kann. Eine besondere und aufwendige spanabhebende Bearbeitung der Lauffläche der Buchse ist in den meisten Fällen nicht erforderlich, da die Lauffläche eine Form entsprechend der Oberfläche des Formkörpers besitzt.The outer circumferential surface of the molded body is hard chrome-plated and optionally provided with a non-stick spray, so that the finished bushing can be easily removed from the molded body. A special and complex machining of the tread of the bush is not necessary in most cases, since the tread has a shape corresponding to the surface of the molded body.

Die erfindungsgemäßen Zylinderlaufbuchsen wurden in Motorversuchen getestet. Dabei war die Zylinderlaufbuchse auch in Dauerlauftestversuchen optimal verschleißfest und lief störungsfrei.The cylinder liners according to the invention were tested in engine tests. The cylinder liner was also optimally wear-resistant in endurance tests and ran trouble-free.

Durch die Erfindung ist somit eine Zylinderlaufbuchse geschaffen, die nach dem erfindungsgemäßen Verfahren einfach und kostengünstig hergestellt werden kann. Die erfindungsgemäße Laufbuchse kann mit optimalen Verschleißfestigkeitswerten und tribologischen Eigenschaften hergestellt werden. Gleichzeitig ist die Zylinderlaufbuchse mit dünnwandiger Geometrie für praktisch alle Motortypen herstellbar.The invention thus creates a cylinder liner that can be produced simply and inexpensively by the method according to the invention. The liner according to the invention can be manufactured with optimal wear resistance values and tribological properties. At the same time, the cylinder liner with thin-walled geometry can be manufactured for practically all engine types.

Die Erfindung ist anhand eines Ausführungsbeispieles in der Zeichnung dargestellt. Die Zylinderlaufbuchse (1) ist aus drei übereinanderliegenden thermischen Spritzschichten gebildet. Die Innenschicht (2) der Zylinderlaufbuchse besteht aus einer verschleißfesten und brandspursicheren Molybdänschicht. Sie bildet die Lauffläche für die Kolbenringe und begrenzt den Brennraum der Verbrennungskammer. Auf die äußere Umfangsfläche der Molybdänschicht (2) ist eine niedrig schmelzende Kobaltlegierung als Haftzwischenschicht (3) aufgetragen und die Außenschicht (4) der Zylinderlaufbuchse (1) besteht aus einer Aluminiumlegierung als Deckschicht. Die Übergänge zwischen den einzelnen Schichten (2,3,4) können gradiert ausgeführt werden.The invention is illustrated in the drawing using an exemplary embodiment. The cylinder liner (1) is formed from three superimposed thermal spray layers. The inner layer (2) of the cylinder liner consists of a wear-resistant and fire-proof molybdenum layer. It forms the running surface for the piston rings and limits the combustion chamber of the combustion chamber. A low-melting cobalt alloy is applied as an intermediate adhesive layer (3) to the outer peripheral surface of the molybdenum layer (2), and the outer layer (4) of the cylinder liner (1) consists of an aluminum alloy as a cover layer. The transitions between the individual layers (2, 3, 4) can be carried out in a graded manner.

Claims (3)

  1. Cylinder liner for a combustion engine to be inserted into the cylinder bore of an engine block, the cylinder liner (1) being produced in a free-forming method by thermal spraying of spray material onto a mandrel serving as a moulded article, forming a cylinder wall, characterised in that the cylinder wall of the cylinder liner comprises a thermally applied anti-abrasion layer (2) at the inner circumference, a bonding intermediate layer (3) applied to the anti-abrasion layer (2) and an outer layer (4) applied thereto on the outer circumference.
  2. Cylinder liner according to patent claim 1, characterised in that the cylinder wall of the cylinder liner (1) has a wall thickness of 1 mm and more.
  3. Method of manufacturing the cylinder liner (1) according to at least one of patent claims 1 and 2 by thermally spraying spray material onto the outer surface of a rotating mandrel serving as a moulded article and then removing the formed cylinder liner (1) from the mandrel and subsequent machining of the end faces of the cylinder liner (1), characterised in that the outer peripheral surface of the mandrel serving as the moulded article is provided with a hard-chrome plated layer which is sand-blasted before the thermal spraying to form the cylinder liner (1) and/or treated with an anti-adhesive spray, the cylinder wall of the cylinder liner comprising a thermally sprayed-on anti-abrasion layer (2) on the inner circumference, a bonding intermediate layer (3) applied to the anti-abrasion layer (2) and an outer layer (4) sprayed onto same at the outer circumference.
EP97100662A 1996-02-17 1997-01-17 Circuit liner unit for an internal combustion engine and method of fabrication Expired - Lifetime EP0790397B1 (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
DE19605946A DE19605946C1 (en) 1996-02-17 1996-02-17 Cylinder liner for internal combustion engines and their manufacturing process
DE19605946 1996-02-17

Publications (2)

Publication Number Publication Date
EP0790397A1 EP0790397A1 (en) 1997-08-20
EP0790397B1 true EP0790397B1 (en) 2001-09-19

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EP97100662A Expired - Lifetime EP0790397B1 (en) 1996-02-17 1997-01-17 Circuit liner unit for an internal combustion engine and method of fabrication

Country Status (4)

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US (1) US5829405A (en)
EP (1) EP0790397B1 (en)
AT (1) ATE205913T1 (en)
DE (2) DE19605946C1 (en)

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DE102013221617A1 (en) * 2013-10-24 2015-04-30 Federal-Mogul Burscheid Gmbh Thin-walled insert for a cylinder of a piston engine and method for its production

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DE59704627D1 (en) 2001-10-25
DE19605946C1 (en) 1997-07-24
EP0790397A1 (en) 1997-08-20
US5829405A (en) 1998-11-03
ATE205913T1 (en) 2001-10-15

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