EP1124660B2 - Zylinderkurbelgehäuse, verfahren zur herstellung der zylinderlaufbuchsen dafür und verfahren zur herstellung des zylinderkurbelgehäuses mit diesen zylinderlaufbuchsen - Google Patents

Zylinderkurbelgehäuse, verfahren zur herstellung der zylinderlaufbuchsen dafür und verfahren zur herstellung des zylinderkurbelgehäuses mit diesen zylinderlaufbuchsen Download PDF

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Publication number
EP1124660B2
EP1124660B2 EP00954591A EP00954591A EP1124660B2 EP 1124660 B2 EP1124660 B2 EP 1124660B2 EP 00954591 A EP00954591 A EP 00954591A EP 00954591 A EP00954591 A EP 00954591A EP 1124660 B2 EP1124660 B2 EP 1124660B2
Authority
EP
European Patent Office
Prior art keywords
layer
cylinder
spraying
bonding layer
alloy
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
EP00954591A
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German (de)
English (en)
French (fr)
Other versions
EP1124660B1 (de
EP1124660A1 (de
Inventor
Dietmar Hoffmann
Josef Steibl
Frank Dörnenburg
Markus Nolte
Achim Sach
Berthold Aumüller
Klaus Dotzler
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.)
ATZ-Evus applikations- und Technikzentrum
Hydro Aluminium Deutschland GmbH
Bayerische Motoren Werke AG
Original Assignee
ATZ-Evus applikations- und Technikzentrum
Hydro Aluminium Deutschland GmbH
Bayerische Motoren Werke AG
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
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Application filed by ATZ-Evus applikations- und Technikzentrum, Hydro Aluminium Deutschland GmbH, Bayerische Motoren Werke AG filed Critical ATZ-Evus applikations- und Technikzentrum
Publication of EP1124660A1 publication Critical patent/EP1124660A1/de
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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 
    • F02F1/004—Cylinder liners
    • 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 
    • F02F1/02—Cylinders; Cylinder heads  having cooling means
    • F02F1/10—Cylinders; Cylinder heads  having cooling means for liquid cooling
    • 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
    • F02F7/00—Casings, e.g. crankcases
    • 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
    • F05C2253/00—Other material characteristics; Treatment of material
    • F05C2253/12—Coating
    • 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
    • Y10T29/49231—I.C. [internal combustion] engine making
    • 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

Definitions

  • the invention relates to a method for producing cylinder liners for a cylinder crankcase.
  • gray cast iron For lightweight construction reasons, a substitution of gray cast iron by aluminum alloys is currently being carried out in cylinder crankcases of internal combustion engines for motor vehicles. While the material of gray cast iron is also suitable for the cylinder running surfaces, cast aluminum alloys in this area are reinforced by cylinder liners.
  • a cylinder liner which consists of a running layer of molybdenum and an outer layer of an aluminum alloy, which is profiled on its outer side. Both layers are formed by thermal spraying on a rotating mandrel.
  • molybdenum an anti-sticking agent, a mandrel with a hard chrome layer and the like, the adhesion of the overlay to the mandrel is reduced to such an extent that the bushes can be pulled off the mandrel.
  • the oxide skin on an aluminum body which is to be poured into a cast aluminum material, prevents the connection to the casting material, is after DE 197 45 725 A1 the oxide skin on the sprue body mechanically destroyed by thermal spraying, wherein the resulting oxide particles are distributed in the sprayed layer.
  • the sprayed-on particles which are not completely melted on impact, protrude from the sprayed layer, whereby the connection with the casting material is improved.
  • the spray material used is a nickel or molybdenum alloy.
  • a method for producing a cylinder liner in which serving as a shaped body mandrel forming a tread, for example of a molybdenum alloy, and on the tread layer, a cover layer, for example of an aluminum alloy, are applied by a thermal spraying process.
  • the coated on its inner surfaces liner is inserted into a finished cast cylinder block.
  • the solid material is provided with a coating which exothermically reacts with the metal casting material during casting and thereby produces intermetallic compounds on the surface of the solid material. In this way, the connection of the solid material to the casting material is to be improved.
  • the solid material may be, for example, a cylinder liner used in an internal combustion engine.
  • the latent exothermic coating is preferably applied by thermal spraying.
  • an aluminum cylinder crankcase with cast-in cylinder liners known.
  • a coating for example a zinc coating
  • the coating is applied by pickling with zincate solution.
  • an additional protective layer may be applied to the liner to prevent oxidation of the molten aluminum used in the casting if the zinc coating alone is not sufficiently thick.
  • This additional protective layer can be applied as a spray coating.
  • the protective layer has the lowest possible porosity. To achieve this, the coating is applied under an inert atmosphere.
  • the object of the invention was to provide a method for the production of cylinder liners which can be ensured in the finished casting in a simple way, the secure fit of the liners.
  • the outer bonding layer is formed by thermal spraying, which is carried out in such a way that a sprayed layer having a high open porosity of at least 10% by volume, in particular 30-70% by volume, is formed.
  • the layer thickness of the attachment layer is preferably 60 ⁇ m-800 ⁇ m, in particular 100 ⁇ m-500 ⁇ m.
  • the bonding layer is preferably produced with a coarse-grained spray powder having a particle size of 60 ⁇ m-400 ⁇ m, in particular 90 ⁇ m-250 ⁇ m.
  • the average particle size of the spray powder of the bonding layer is thus preferably more than 100 ⁇ m, in particular more than 130 ⁇ m. If such a coarse-grained spray powder is used to spray a very thin bonding layer, instead of an open-porous layer only a layer of correspondingly high roughness can be formed.
  • Light metals ie in particular aluminum and magnesium and their alloys, namely form an outer oxide layer in the molten state, which is formed by the reaction of the light metal with the ambient oxygen.
  • the oxide skin protects the melt flowing inside from further oxidation.
  • the high roughness or open porosity of the bonding layer of the cylinder liner according to the invention causes the oxide skin of a flowing light metal melt to rupture again and again so that a direct contact between the melt and the surface of the bonding layer takes place.
  • the oxide skin of the melt is thus pierced continuously by the fine tips of the porous, rough surface of the bonding layer produced by thermal spraying.
  • the melt After rupturing the oxide skin, the melt infiltrates the porous attachment layer. This results in a direct contact between the melt and the surface of the bonding layer, which leads to a cohesive connection.
  • melting of the bonding layer takes place on the surface. In this way, a high cohesive degree of connection between the bonding layer of the cylinder liner and the cylinder crankcase is obtained. That is, according to the invention, based on the cylindrical lateral surface of the bonding layer at least 60%, preferably at least 80% and in particular at least 90% of the bonding layer of the cylinder liner with the casting material of the cylinder crankcase connected by material bond.
  • the degree of connection can be determined by ultrasound.
  • inventively thermally sprayed, tribologically optimized cylinder liners can be poured into commercially available, inexpensive aluminum alloys.
  • the thermal spraying offers the advantage that, in comparison to other techniques, it is possible to choose a composition of materials which is almost freely selectable and corresponds to local requirements.
  • the cylinder liner produced according to the invention by thermal spraying can be adapted alloyed both tread side in terms of tribological properties and engine block side with regard to the connection.
  • the material forming the cylinder surface must also be resistant to corrosion. He must also be machined, so that the cylinder liner can be brought to functional size after pouring.
  • a carrier layer is preferably thermally sprayed onto a mandrel as a shaped body. After the carrier layer has been sprayed on, the running layer is applied to the carrier layer by thermal spraying and then the tying layer is applied to the overlay by thermal spraying.
  • the cylinder liner blank thus produced is then removed from the mandrel, wherein the carrier layer facilitates the detachment of the blank from the mandrel by their low adhesion to the mandrel.
  • the blanks are placed in the mold on sleeves. After casting and removal of the cylinder crankcase, the support layer is removed by machining and the running layer is brought to its functional dimension.
  • thermal spraying all known process variants can be used; This applies both to the spray materials (powder or wire) and to the type of energy carrier (flame, arc, plasma).
  • the cylinder liner produced according to the invention has sufficient dimensional stability, it preferably has a wall thickness of 1 mm to 5 mm.
  • the socket can thus be easily stored and handled from the production to the sprue.
  • cylinder liners can be produced with standard diameters and lengths for all common engine types.
  • the mandrel is preferably made of tool steel or other material that is not melted during thermal spraying. During thermal spraying of the individual layers of the cylinder liner according to the invention, the mandrel is set in rotation.
  • the mandrel has the same dimensions as the sleeves. Accordingly, the mandrel with the same cone angle of z. B. 0.5 ° as the sleeves are tapered to be able to fit the cylinder liner blanks accurately on the sleeves.
  • the mandrel may be hollow to cool it with a medium such as water. After thermal spraying, the mandrel can then be shrunk by cooling from the still hot thermal cylinder liner blank. Also, the mandrel can be removed by pressing out of the cylinder liner blank.
  • the carrier layer is preferably produced by flame spraying with spray wire, since this method can be carried out particularly economically.
  • Tin, zinc, aluminum and their alloys are preferably used as the spraying materials, since on the one hand they lead to sufficient adhesion of the carrier layer to the mandrel and on the other hand to ensure that the finished molded bushing can be detached from the mandrel in a simple manner.
  • the carrier layer preferably has a thickness of 20 ⁇ m to 500 ⁇ m, in particular 50 ⁇ m to 100 ⁇ m.
  • the carrier layer is generally required in the cylinder liner according to the invention in particular when the overlay consists of a light metal alloy which would adhere to the mandrel without a carrier layer such that the cylinder liner can not be detached from the mandrel without destruction.
  • the running layer which for weight reasons according to the invention consists of a light metal alloy, in particular an aluminum or magnesium alloy, namely a tribologically suitable, corrosion-resistant light metal alloy, is preferably an aluminum-silicon alloy having a Si content of in particular 12 to 50 wt.%.
  • a Si content of ⁇ 12 wt.% With a Si content of ⁇ 12 wt.%, The tribological properties leave something to be desired, with a Si content of> 50%, the material is usually brittle and therefore difficult to work.
  • the light metal alloy may contain other tribologically active additives, for example silicon carbide, graphite or molybdenum.
  • an Al-Si alloy may also contain the following alloying ingredients by weight: Fe 0.5-2.0%, preferably 0.5-1.5% Ni 0.5-2.0%, preferably 0.5-1.5% mg 0, 5 - 2.0%, preferably 0, 5 - 1.5% Cu 0.5-2.0%, preferably 0.5-1.5%
  • Tread production can be accomplished by atmospheric plasma spraying (APS), flame spraying and high velocity flame spraying (HVOF) with a spray powder. Also, a special method in the field of high speed flame spraying, which has become known as CGDM (Cold Gas Dynamic Spray Method), can be applied.
  • APS atmospheric plasma spraying
  • HVOF high velocity flame spraying
  • CGDM Cold Gas Dynamic Spray Method
  • the average particle size is preferably below 100 .mu.m, in particular below 80 .mu.m, preferably a sieve fraction between 10 .mu.m and 125 .mu.m is used in order to obtain a tribologically suitable corrosion-resistant and machinable tread.
  • the running layer can also be produced with wire-shaped spray materials, for example by wire flame spraying or arc spraying. However, because of the greater choice of material, powder spraying is generally preferred.
  • the running layer preferably has a Thickness of 0.5 mm to 3 mm, in particular 1 mm to 2 mm.
  • the formation of the porous bonding layer of the cylinder liner according to the invention can be achieved by using a spray powder with a correspondingly large particle size and a suitable thermal spraying process.
  • the spray powder preferably has a mean particle size between 60 ⁇ m and 400 ⁇ m, in particular more than 100 ⁇ m, in particular more than 150 ⁇ m.
  • a sieve fraction between 90 microns and 250 microns is used.
  • all powder processes can be used, in particular flame or plasma spraying. When flame spraying, a spray distance of 50 mm to 400 mm, in particular 100 mm to 250 mm can be applied.
  • the spray material for the bonding layer consists of a similar light metal alloy. That is, since the casting material is usually an aluminum alloy, the bonding layer is also made of aluminum alloy. However, it is also a casting material and a bonding layer, e.g. conceivable from a magnesium alloy.
  • the material used for spraying the bonding layer is preferably adapted on the one hand to the running layer material and on the other hand to the casting material. That is, if the casting alloy is made of an Al-Si alloy and the overlay is made of an Al-Si alloy, an Al-Si alloy is also preferably used for the bonding layer.
  • the Si content of the Al-Si alloy of the attachment layer is preferably between the Si content of the Al-Si casting alloy and that of the overlay alloy.
  • the Si content of the Al-Si Alloy of the bonding layer for example, between 10 and 25 wt.% Be. It is also possible to carry out a graded transition of the composition of the bonding layer between the overlay and the cast alloy by corresponding change of the spray material during the spraying of the bonding layer. Also, by changing the process parameters, the porosity of the bonding layer can be changed from the running layer to the casting material.
  • the thickness of the bonding layer can be 60 ⁇ m to 800 ⁇ m; preferably it is between 100 microns and 500 microns.
  • thermally sprayed cylinder liner blank can be poured into the cylinder crankcase immediately after the injection process.
  • the cylinder liner blank is subjected to a heat treatment before the sprue in order to obtain a stable structure by artificial aging.
  • the heat treatment may be carried out at a temperature between 300 ° C and 550 ° C for half an hour to several hours.
  • the temperature of the melt is preferably above the melting temperature of the bonding layer of the cylinder liner to melt to improve the material connection, the bonding layer on its surface during casting.
  • the formation of the interface between the casting material and the cylinder liner is significantly influenced by the casting process used.
  • the gravitational process can be carried out for casting, pressure-assisted casting processes are preferred according to the invention compared with pressure-limited casting processes.
  • a mandrel (hollow mandrel) made of tool steel with a taper of 0.5 ° is circulated at a speed of 180 rpm.
  • On the mandrel is applied by flame spraying with a wire of zinc at a spray distance of about 100 mm to 150 mm on its outer cylindrical support layer with a thickness of about 70 microns.
  • the mandrel is quenched with cold water and thus solved by shrinking from the still hot cylinder liner blank.
  • the blank is then placed on the quill in a mold and cast by die casting with an Al-Si alloy with a Si content of 9 wt.%. After removal from the mold, the carrier layer is removed by machining and the running layer is brought to the cylindrical functional dimension.

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  • Engineering & Computer Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Combustion & Propulsion (AREA)
  • Mechanical Engineering (AREA)
  • General Engineering & Computer Science (AREA)
  • Cylinder Crankcases Of Internal Combustion Engines (AREA)
  • Coating By Spraying Or Casting (AREA)
EP00954591A 1999-08-11 2000-08-05 Zylinderkurbelgehäuse, verfahren zur herstellung der zylinderlaufbuchsen dafür und verfahren zur herstellung des zylinderkurbelgehäuses mit diesen zylinderlaufbuchsen Expired - Lifetime EP1124660B2 (de)

Applications Claiming Priority (3)

Application Number Priority Date Filing Date Title
DE19937934A DE19937934A1 (de) 1999-08-11 1999-08-11 Zylinderkurbelgehäuse, Verfahren zur Herstellung der Zylinderlaufbuchsen dafür und Verfahren zur Herstellung des Zylinderkurbelgehäuses mit diesen Zylinderlaufbuchsen
DE19937934 1999-08-11
PCT/EP2000/007615 WO2001012362A1 (de) 1999-08-11 2000-08-05 Zylinderkurbelgehäuse, verfahren zur herstellung der zylinderlaufbuchsen dafür und verfahren zur herstellung des zylinderkurbelgehäuses mit diesen zylinderlaufbuchsen

Publications (3)

Publication Number Publication Date
EP1124660A1 EP1124660A1 (de) 2001-08-22
EP1124660B1 EP1124660B1 (de) 2005-10-26
EP1124660B2 true EP1124660B2 (de) 2009-11-25

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Application Number Title Priority Date Filing Date
EP00954591A Expired - Lifetime EP1124660B2 (de) 1999-08-11 2000-08-05 Zylinderkurbelgehäuse, verfahren zur herstellung der zylinderlaufbuchsen dafür und verfahren zur herstellung des zylinderkurbelgehäuses mit diesen zylinderlaufbuchsen

Country Status (7)

Country Link
US (2) US20020033161A1 (cs)
EP (1) EP1124660B2 (cs)
AT (1) ATE307694T1 (cs)
CZ (1) CZ20011285A3 (cs)
DE (2) DE19937934A1 (cs)
HU (1) HUP0104219A3 (cs)
WO (1) WO2001012362A1 (cs)

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EP1124660B1 (de) 2005-10-26
HUP0104219A3 (en) 2002-11-28
EP1124660A1 (de) 2001-08-22
CZ20011285A3 (cs) 2002-02-13
WO2001012362A1 (de) 2001-02-22
ATE307694T1 (de) 2005-11-15
US7073492B2 (en) 2006-07-11
US20020033161A1 (en) 2002-03-21
DE19937934A1 (de) 2001-02-15
DE50011441D1 (de) 2005-12-01
US20040154577A1 (en) 2004-08-12

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