EP1161569B2 - Method and system for producing wear-resistant surfaces - Google Patents

Method and system for producing wear-resistant surfaces Download PDF

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Publication number
EP1161569B2
EP1161569B2 EP00902632A EP00902632A EP1161569B2 EP 1161569 B2 EP1161569 B2 EP 1161569B2 EP 00902632 A EP00902632 A EP 00902632A EP 00902632 A EP00902632 A EP 00902632A EP 1161569 B2 EP1161569 B2 EP 1161569B2
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EP
European Patent Office
Prior art keywords
cooling
cylinder
thermally conductive
coating
wear
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EP00902632A
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German (de)
French (fr)
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EP1161569A1 (en
EP1161569B1 (en
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Rolf Heinemann
Klaus Färber
Thomas Heider
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Volkswagen AG
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Volkswagen AG
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Priority claimed from DE19941562A external-priority patent/DE19941562A1/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
    • C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
    • C23C4/12—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge characterised by the method of spraying
    • C23C4/14—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge characterised by the method of spraying for coating elongate material
    • C23C4/16—Wires; Tubes
    • 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
    • C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
    • C23C4/12—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge characterised by the method of spraying
    • 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
    • C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
    • C23C4/18—After-treatment

Definitions

  • the invention relates to a method for producing wear-resistant surfaces on components of an Al-Si alloy, wherein the wear-resistant surfaces by means of thermal spraying, in particular flame spraying, plasma spraying or HV spraying, or a laser beam is applied, according to the preamble of claim 1.
  • the invention further relates to an arrangement for producing wear-resistant surfaces on components made of an Al-Si alloy, in particular on cylinder surfaces of cylinders of a crankcase of a reciprocating internal combustion engine, according to the preamble of claim 6.
  • hypoeutectic aluminum-silicon alloys are unsuitable due to the low proportion of wear-resistant silicon phase for the tribological stress of the system piston-piston ring cylinder bore.
  • Hypereutectic alloys such as the alloy AlSil 7 Cu 4 Mg have a sufficient amount of silicon crystallites.
  • This hard, wear-resistant structural constituent is emphasized by chemical and / or mechanical processing steps in relation to the matrix consisting of the aluminum mixed crystal and forms a required aerofoil fraction.
  • a disadvantage is the lack of castability, the poor machinability and the high cost of this alloy compared to the hypoeutectic and near-eutectic alloys.
  • under- and near-eutectic alloys of the galvanic coatings are applied directly to the raceways.
  • this is expensive and Tribochemically insufficient resistant.
  • thermal spray coatings which are also applied directly to the treads.
  • the adhesive strength of these layers is insufficient due to a sole micromechanical clamping.
  • DE 196 43 029 A1 It has therefore already been proposed to carry out the surface modifications remelting, alloying, dispersing and coating by the use of a laser, as known for example from DE 196 43 029 A1. In this case, it is necessary to dissipate the energy introduced by the laser beams into the crankcase or the cylinder running surfaces sufficiently quickly. Too high an input of heat with high-energy laser beams can lead to unwanted structural changes in the crankcase. For this purpose, DE 196 43 029 A1 already proposes to cool the component surface via cooling water passages of the crankcase.
  • the present invention has for its object, an improved method of the above type and an improved arrangement of the above.
  • To make available type which allows a coating of components with high-energy coating devices, such as high-performance lasers, without thermally induced changes in the material of the component.
  • the wear-resistant surface after the wear-resistant surface has been formed in the form of a thermal spray coating, it is additionally processed with a laser beam, in particular remelted.
  • a remelting, Einiegieren, dispersing and / or coating carried out by means of a laser beam or by thermal spraying.
  • the component is a crankcase of a reciprocating internal combustion engine, on whose cylinder surfaces of cylinders, the coating is performed.
  • a water space of the crankcase flows through a cooling medium, in particular gas, nitrogen or a cooling liquid.
  • a heat-conducting device which is arranged in heat-conducting physical contact with the component and comprises a cooling medium.
  • the heat-conducting device comprises at least one cooling cylinder corresponding to the cross section of a cylinder bore and circumferentially on the cylinder wall with flowed through by the cooling medium channels, which is arranged in the axial direction of the cylinder on one or both sides of a coating zone such that a thermally conductive contact between the cooling mandrel the cylinder running surface is formed.
  • the cooling medium comprises a gas, nitrogen and / or a cooling liquid, which provide a high heat capacity coefficient for a correspondingly high heat dissipation.
  • the channels through which the cooling medium flows are formed in a spiral shape.
  • a cooling mandrel arranged in the direction of gravity below the coating zone is provided with a collecting basin for excess coating material.
  • a collecting nose is formed on a side of the circumference of the cooling mandrel facing the coating zone.
  • the cooling mandrel of the cooling mandrel is formed on its cylinder surface facing the circumference with cooling bristles, which are in brushing contact with the cylinder surface.
  • the cooling bristles are made of a thermally conductive material, in particular copper.
  • the illustrated in Fig. 1 embodiment of an inventive arrangement comprises a coating apparatus 10, which by means of a plasma jet 12, which is for example a laser beam, a cylinder surface 14 of a cylinder wall 15 of a cylinder 16 of a crankcase 18 coated.
  • the coating apparatus 10 is rotatable about a longitudinal axis 20, as with arrow 22 indicated, and slidable along the longitudinal axis 20, as indicated by arrow 24.
  • the crankcase 18 has a water space 26 for a cooling medium. Due to the rotational and translational movement of the coating apparatus 10 relative to the cylinder wall 15, the cylinder running surface 14 can be processed in predetermined areas.
  • the assembly comprises a cooling plate 30 which is constructed, i. is made by a plate system or mechanically, or cast and includes cooling channels 32, which are traversed by the cooling medium.
  • the cooling channels have, for example, a rectangular and / or round cross-section and are in particular formed above a contact surface 34 between the cooling plate 30 and the cylinder wall 15.
  • a cooling plate 30 is arranged either on one side or on both sides of the open ends of the cylinder 16. Further, the cooling plates are annular according to the cylinder cross-section so that they rest on the circumferential cylinder wall 15 and provide an opening for introducing the coating device 10 in the ring.
  • the lower cooling plate 30 in FIG. 1 has the further advantage, in the case of an annular design, that process gases and excess coating material which is not melted or does not adhere to the cylinder bore 14 can be removed downward in the direction of gravity in FIG.
  • the arrangement comprises a cooling mandrel 36, which is formed according to the cross section of the cylinder 16 such that this cooling mandrel 36 is inserted into the cylinder 16 and abuts there in the circumferential direction of the cylinder wall 15.
  • cooling bristles 38 for example copper, are provided on the jacket of the cooling mandrel 38, which are in contact with the surface of the cylinder wall 15 and in this way heat from the cylinder wall 15 to the cooling mandrel 36 derived.
  • cooling mandrel cooling channels 40 are further provided by a cooling medium, which serve in the aforementioned manner for active cooling and heat energy dissipation.
  • the cooling channels are formed spirally encircling.
  • a collecting bowl 42 formed on the lower cooling mandrel 36 in FIG. 1 particles adhering to the cylinder wall 15 are not collected.
  • the catch basin 42 is gehelit with cooling medium.
  • An additional catch nose 44 directs excess, falling coating material in the catch basin 42.
  • ademediumzufluß 46 and ademediumabfluß 48 is provided for the cooling medium in the catch basin 42 and / or in the cooling channels 40.
  • one or both of the cooling mandrels 36 shown in FIG. 1 are entrained in the direction of arrow 24 at the feed rate of the coating device, as indicated by arrows 50.
  • honing may also take place after the coating, wherein the honing process may comprise several steps depending on the desired surface quality.
  • a cooling fluid such as gas, nitrogen or a cooling liquid is passed, resulting in further cooling of the cylinder wall 15 leads and thus additionally dissipates heat from the coating zone.

Description

Die Erfindung betrifft ein Verfahren zum Herstellen verschleißfester Oberflächen an Bauteilen aus einer Al-Si-Legierung, wobei die verschleißfeste Oberflächen mittels eines thermischen Spritzens, insbesondere Flammspritzen, Plasmaspritzen oder HV-Spritzen, oder eines Laserstrahles aufgebracht wird, gemäß dem Oberbegriff des Anspruchs 1. Die Erfindung betrifft ferner eine Anordnung zum Herstellen verschleißfester Oberflächen an Bauteilen aus einer Al-Si-Legierung, insbesondere an Zylinderlaufflächen von Zylindern eines Kurbelgehäuses einer Hubkolben-Brennkraftmaschine, gemäß dem Oberbegriff des Anspruchs 6.The invention relates to a method for producing wear-resistant surfaces on components of an Al-Si alloy, wherein the wear-resistant surfaces by means of thermal spraying, in particular flame spraying, plasma spraying or HV spraying, or a laser beam is applied, according to the preamble of claim 1. The invention further relates to an arrangement for producing wear-resistant surfaces on components made of an Al-Si alloy, in particular on cylinder surfaces of cylinders of a crankcase of a reciprocating internal combustion engine, according to the preamble of claim 6.

Die für Zylinderkurbelgehäuse vorwiegend eingesetzten untereutektischen Aluminium-Silizium-Legierungen sind aufgrund des zu geringen Anteils der verschleißfesten Siliziumphase für die tribologische Beanspruchung des Systems Kolben-Kolbenring-Zylinderlaufbahn ungeeignet. Übereutektische Legierungen, z.B. die Legierung AlSil7Cu4Mg besitzen einen ausreichenden Anteil an Siliziumkristalliten. Dieser harte, verschleißbeständige Gefügebestandteil wird durch chemische und/oder mechanische Bearbeitungsstufen gegenüber der aus dem Aluminiummischkristall bestehenden Matrix hervorgehoben und bildet einen erforderlichen Tragflächenanteil. Nachteilig wirkt sich jedoch die gegenüber den untereutektischen und naheutektischen Legierungen mangelhafte Vergießbarkeit, die schlechte Bearbeitbarkeit und die hohen Kosten für diese Legierung aus.The predominantly used for cylinder crankcases hypoeutectic aluminum-silicon alloys are unsuitable due to the low proportion of wear-resistant silicon phase for the tribological stress of the system piston-piston ring cylinder bore. Hypereutectic alloys, such as the alloy AlSil 7 Cu 4 Mg have a sufficient amount of silicon crystallites. This hard, wear-resistant structural constituent is emphasized by chemical and / or mechanical processing steps in relation to the matrix consisting of the aluminum mixed crystal and forms a required aerofoil fraction. A disadvantage, however, is the lack of castability, the poor machinability and the high cost of this alloy compared to the hypoeutectic and near-eutectic alloys.

Eine Möglichkeit zur Umgehung dieses Nachteils ist das Eingießen von Laufbuchsen aus verschleißbeständigem Material wie z.B. Grauguß- und, übereutektischen Aluminiumlegierungen. Problematisch ist hier jedoch die Verbindung zwischen Buchse und Umguß, welcher alleine durch eine mechanische Verzahnung gewährleistet wird. Durch Einsatz eines porösen keramischen Buchsenwerkstoffs ist es möglich, beim Gießprozeß diesen zu infiltrieren und zu einer stofflichen Verbindung zu gelangen. Dazu ist eine langsame Formfüllung sowie die Anwendung von hohem Druck erforderlich, was die Wirtschaftlichkeit des Verfahrens erheblich herabsetzt.One way of overcoming this disadvantage is to pour bushings of wear resistant material such as e.g. Gray cast iron and hypereutectic aluminum alloys. However, the problem here is the connection between the bushing and casting, which is ensured solely by a mechanical toothing. By using a porous ceramic bushing material, it is possible during the casting process to infiltrate this and to achieve a material connection. For this purpose, a slow mold filling and the application of high pressure is required, which significantly reduces the cost of the process.

Alternativ werden unter- und naheutektischen Legierungen der galvanische Beschichtungen direkt auf die Laufbahnen aufgebracht. Dies ist jedoch teuer und tribochemisch nur ungenügend beständig. Eine weitere Alternative bilden thermische Spritzschichten, welche ebenfalls direkt auf die Laufflächen appliziert werden. Die Haftfestigkeit dieser Schichten ist jedoch aufgrund einer alleinigen mikromechanischen Verklammerung nur ungenügend.Alternatively, under- and near-eutectic alloys of the galvanic coatings are applied directly to the raceways. However, this is expensive and Tribochemically insufficient resistant. Another alternative form thermal spray coatings, which are also applied directly to the treads. However, the adhesive strength of these layers is insufficient due to a sole micromechanical clamping.

Es wurde daher bereits vorgeschlagen, die Oberflächenmodifikationen Umschmelzen, Einlegieren, Dispergieren und Beschichten durch den Einsatz eines Lasers auszuführen, wie beispielsweise aus der DE 196 43 029 A1 bekannt. Hierbei es ist erforderlich, die durch die Laserstrahlen in das Kurbelgehäuse bzw. die Zylinderlaufflächen eingebrachte Energie ausreichend schnell abzuführen. Ein zu hoher Wärmeeintrag bei energiereichen Laserstrahlen kann nämlich zu unerwünschten Gefügeveränderungen im Kurbelgehäuse führen. Hierzu wird von der DE 196 43 029 A1 bereits vorgeschlagen, die Bauteiloberfläche über Kühlwasserkanäle des Kurbelgehäuses zu kühlen.It has therefore already been proposed to carry out the surface modifications remelting, alloying, dispersing and coating by the use of a laser, as known for example from DE 196 43 029 A1. In this case, it is necessary to dissipate the energy introduced by the laser beams into the crankcase or the cylinder running surfaces sufficiently quickly. Too high an input of heat with high-energy laser beams can lead to unwanted structural changes in the crankcase. For this purpose, DE 196 43 029 A1 already proposes to cool the component surface via cooling water passages of the crankcase.

Der vorliegenden Erfindung liegt die Aufgabe zugrunde, ein verbessertes Verfahren der obengenannten Art sowie eine verbesserte Anordnung der o.g. Art zur Verfügung zu stellen, welche eine Beschichtung von Bauteilen auch mit hochenergetischen Beschichtungsvorrichtungen, wie beispielsweise leistungsstarken Lasern, ohne thermisch bedingte Veränderungen des Werkstoffes des Bauteiles erlaubt.The present invention has for its object, an improved method of the above type and an improved arrangement of the above. To make available type, which allows a coating of components with high-energy coating devices, such as high-performance lasers, without thermally induced changes in the material of the component.

Diese Aufgabe wird erfindungsgemäß durch ein Verfahren der o.g. Art mit den in Anspruch 1 gekennzeichneten Merkmalen und durch eine Anordnung der o.g. Art mit den in Anspruch 6 gekennzeichneten Merkmalen gelöst. Vorteilhafte Ausgestaltungen der Erfindung sind in den abhängigen Ansprüchen angegeben.This object is achieved by a method of o.g. Art having the features characterized in claim 1 and by an arrangement of o.g. Art solved with the features characterized in claim 6. Advantageous embodiments of the invention are specified in the dependent claims.

Bei einem Verfahren der o.g. Art ist es erfindungsgemäß vorgesehen, daß während der Herstellung der verschleißfesten Oberfläche wenigstens eine wärmeleitende Vorrichtung in wärmeleitenden Berührungskontakt mit dem Bauteil gebracht und diese wärmeleitende Vorrichtung aktiv gekühlt wird, wobei die wärmeleitende Vorrichtung wenigstens einen dem Querschnitt des Zylinders entsprechenden und in Umfangsrichtung an der Zylinderwand anliegenden Kühldorn, umfasst welcher in axialer Richtung des Zylinders einer Beschichtungszone folgend und/oder der Beschichtungszone nacheilend mit der Zylinderlauffläche in Kontakt gebracht wird.In a method of o.g. It is inventively provided that during the manufacture of the wear-resistant surface at least one heat-conducting device brought into heat-conducting physical contact with the component and this heat-conducting device is actively cooled, wherein the heat-conducting device corresponding at least one of the cross-section of the cylinder and in the circumferential direction of the cylinder wall Cooling mandrel, which is in the axial direction of the cylinder following a coating zone and / or the coating zone lagging brought into contact with the cylinder surface.

Dies hat den Vorteil, daß eine gute Wärmeabführung mit erhöhter Kühlleistung während des Beschichtungsvorganges zur Verfügung steht, so daß insbesondere ein Lasereinlegieren und Laserbeschichten ohne die Gefahr einer wärmebedingten Strukturveränderung im Werkstoff des Kurbelgehäuses ausgeführt werden kann. Hierdurch ist es möglich, auch mit höheren Energien zu beschichten, so daß beispielsweise eine höhere Eindringtiefe des Beschichtungswerkstoffes in den Werkstoff des Bauteiles, eine bessere Verbindung zwischen der Beschichtung und dem Werkstoff des Bauteiles und/oder eine höhere Schichtdicke erzielt wird.This has the advantage that a good heat dissipation with increased cooling capacity during the coating process is available, so that in particular a laser alloying and laser coating without the risk of heat-induced structural change in the material of the crankcase can be performed. This makes it possible to coat with higher energies, so that, for example, a higher penetration depth of the coating material in the material of the component, a better connection between the coating and the material of the component and / or a higher layer thickness is achieved.

Zum weiteren Verbessern von Eigenschaften der aufgebrachten Beschichtung wird nach dem Ausbilden der verschleißfesten Oberfläche in Form einer thermischen Spritzschicht diese zusätzlich mit einem Laserstrahl bearbeitet, insbesondere umgeschmolzen.To further improve the properties of the applied coating, after the wear-resistant surface has been formed in the form of a thermal spray coating, it is additionally processed with a laser beam, in particular remelted.

In einer bevorzugten Ausführungsform wird daß ein Umschmelzen, Einiegieren, Dispergieren und/oder Beschichten mittels eines Laserstrahles oder durch thermisches Spritzen durchgeführt.In a preferred embodiment, that is a remelting, Einiegieren, dispersing and / or coating carried out by means of a laser beam or by thermal spraying.

Das Bauteil ist ein Kurbelgehäuse einer Hubkolben-Brennkraftmaschinen, an dessen Zylinderlauftlächen von Zylindern die Beschichtung durchgeführt wird. Hierbei wird in einer bevorzugten Ausführungsform während der Herstellung der verschleißfesten Oberfläche ein Wasserraum des Kurbelgehäuses mit einem Kühlmedium, insbesondere Gas, Stickstoff oder einer Kühlflüssigkeit, durchströmt.The component is a crankcase of a reciprocating internal combustion engine, on whose cylinder surfaces of cylinders, the coating is performed. In this case, in a preferred embodiment, during the production of the wear-resistant surface, a water space of the crankcase flows through a cooling medium, in particular gas, nitrogen or a cooling liquid.

Bei einer Anordnung der o.g. Art ist es erfindungsgemäß vorgesehen, daß eine wärmeleitende Vorrichtung vorgesehen ist, welche in wärmeleitendem Berührungskontakt mit dem Bauteil angeordnet ist und ein Kühlmedium umfaßt. Dabei umfaßt die wärmeleitende Vorrichtung wenigstens einen dem Querschnitt einer Zylinderbohrung entsprechenden Kühldorn und in Umfangsrichtung an der Zylinderwand anliegenden mit vom Kühlmedium durchströmten Kanälen, welcher in axialer Richtung des Zylinders ein- oder beidseitig einer Beschichtungszone derart angeordnet ist, daß ein wärmeleitender Kontakt zwischen dem Kühldorn mit der Zylinderlauffläche ausgebildet ist.In an arrangement of o.g. Art, it is inventively provided that a heat-conducting device is provided, which is arranged in heat-conducting physical contact with the component and comprises a cooling medium. In this case, the heat-conducting device comprises at least one cooling cylinder corresponding to the cross section of a cylinder bore and circumferentially on the cylinder wall with flowed through by the cooling medium channels, which is arranged in the axial direction of the cylinder on one or both sides of a coating zone such that a thermally conductive contact between the cooling mandrel the cylinder running surface is formed.

Dies hat den Vorteil, daß eine gute Wärmeabführung mit erhöhter Kühlleistung während des Beschichtungsvorganges zur Verfügung steht, so daß insbesondere ein Lasereinlegieren und Laserbeschichten ohne die Gefahr einer wärmebedingten Strukturveränderung im Werkstoff des Kurbelgehäuses ausgeführt werden kann. Hierdurch ist es möglich, auch mit höheren Energien zu beschichten, so daß beispielsweise eine höhere Eindringtiefe des Beschichtungswerkstoffes in den Werkstoff des Bauteiles, eine bessere Verbindung zwischen der Beschichtung und dem Werkstoff des Bauteiles und/oder eine höhere Schichtdicke erzielt wird.This has the advantage that a good heat dissipation with increased cooling capacity during the coating process is available, so that in particular a laser alloying and laser coating without the risk of heat-induced structural change in the material of the crankcase can be performed. This makes it possible to coat with higher energies, so that, for example, a higher penetration depth of the coating material into the material of the component, a better connection between the coating and the material of the component and / or a higher layer thickness is achieved.

Zweckmäßigerweise umfaßt das Kühlmedium ein Gas, Stickstoff und/oder eine Kühlflüssigkeit, welche mit einem hohen Wärmekapazitätskoeffizienten für einen entsprechend hohen Wärmeabtransport sorgen.Conveniently, the cooling medium comprises a gas, nitrogen and / or a cooling liquid, which provide a high heat capacity coefficient for a correspondingly high heat dissipation.

Für eine hohe Kühlleistung nahe der Zylinderlauffläche sind die vom Kühlmedium durchströmten Kanäle spiralförmig umlaufend ausgebildet.For a high cooling capacity close to the cylinder surface, the channels through which the cooling medium flows are formed in a spiral shape.

Zum Auffangen von überschüssigem Beschichtungsmaterial ist ein in Schwerkraftrichtung unterhalb der Beschichtungszone angeordneter Kühldorn mit einem Auffangbecken für überschüssiges Beschichtungsmaterial ausgebildet.For collecting excess coating material, a cooling mandrel arranged in the direction of gravity below the coating zone is provided with a collecting basin for excess coating material.

Zum Auffangen und Einleiten von überschüssigem Beschichtungsmaterial in das Auffangbecken ist an einer der Beschichtungszone zugewandten Seite des Umfangs des Kühldornes eine Auffangnase ausgebildet.For collecting and introducing excess coating material into the collecting basin, a collecting nose is formed on a side of the circumference of the cooling mandrel facing the coating zone.

Zur Erhöhung einer Kühlwirkung des Kühldornes ist der Kühldorn an seinem der Zylinderlauffläche zugewandten Umfang mit Kühlborsten ausgebildet, welche in bürstendem Kontakt mit der Zylinderlauffläche stehen. Zweckmäßigerweise sind die Kühlborsten aus einem wärmeleitenden Material, insbesondere Kupfer, gefertigt.To increase a cooling effect of the cooling mandrel of the cooling mandrel is formed on its cylinder surface facing the circumference with cooling bristles, which are in brushing contact with the cylinder surface. Conveniently, the cooling bristles are made of a thermally conductive material, in particular copper.

Besonders vorteilhaft ist es, an das erfindungsgemäße Beschichtungsverfahren einen Hon-Vorgang anzuschließen, um die beschichtete Oberfläche zu glätten.It is particularly advantageous to attach a honing process to the coating method according to the invention in order to smooth the coated surface.

Weitere Merkmale, Vorteile und vorteilhafte Ausgestaltungen der Erfindung ergeben sich aus den abhängigen Ansprüchen, sowie aus der nachstehenden Beschreibung der Erfindung anhand der beigefügten Zeichnungen. Diese zeigen in

Fig. 1
in einer Schnittansicht eine Ausführungsform einer erfindungsgemäßen Anordnung.
Further features, advantages and advantageous embodiments of the invention will become apparent from the dependent claims, and from the following description of the invention with reference to the accompanying drawings. These show in
Fig. 1
in a sectional view of an embodiment of an inventive arrangement.

Die in Fig. 1 dargestellte Ausführungsform einer erfindungsgemäßen Anordnung umfaßt eine Beschichtungsvorrichtung 10, welche mittels eines Plasmastrahles 12, welcher beispielsweise ein Laserstrahl ist, eine Zylinderlauffläche 14 einer Zylinderwand 15 eines Zylinders 16 eines Kurbelgehäuses 18 beschichtet. Die Beschichtungsvorrichtung 10 ist um eine Längsachse 20 drehbar, wie mit Pfeil 22 angedeutet, und entlang der Längsachse 20 verschiebbar, wie mit Pfeil 24 angedeutet. Das Kurbelgehäuse 18 weist einen Wasserraum 26 für ein Kühlmedium auf. Durch die Rotations- und Translationsbewegung der Beschichtungsvorrichtung 10 relativ zur Zylinderwandung 15 ist die Zylinderlauffläche 14 in vorbestimmten Bereichen bearbeitbar. Hierbei ist nachfolgend ein aktueller Arbeitsbereich der Beschichtungsvorrichtung 10, in dem der Plasmastrahl 12 oder ein Laserstrahl auf die Zylinderlauffläche 14 trifft, als Bearbeitungszone 28 bezeichnet.The illustrated in Fig. 1 embodiment of an inventive arrangement comprises a coating apparatus 10, which by means of a plasma jet 12, which is for example a laser beam, a cylinder surface 14 of a cylinder wall 15 of a cylinder 16 of a crankcase 18 coated. The coating apparatus 10 is rotatable about a longitudinal axis 20, as with arrow 22 indicated, and slidable along the longitudinal axis 20, as indicated by arrow 24. The crankcase 18 has a water space 26 for a cooling medium. Due to the rotational and translational movement of the coating apparatus 10 relative to the cylinder wall 15, the cylinder running surface 14 can be processed in predetermined areas. Hereinafter, a current working range of the coating apparatus 10, in which the plasma jet 12 or a laser beam impinges on the cylinder running surface 14, referred to as the processing zone 28.

Die Anordnung umfaßt eine Kühlplatte 30, welche gebaut, d.h. mittels Plattensystem oder mechanisch, oder gegossen gefertigt ist und Kühlkanäle 32 umfaßt, welche von dem Kühlmedium durchflossen werden. Auf diese Weise ist die Kühlplatte aktiv gekühlt und führt über die bloße Wärmeleitung hinaus aktiv Wärmeenergie ab. Die Kühlkanäle weisen beispielsweise einen rechteckigen und/oder runden Querschnitt auf und sind insbesondere oberhalb einer Kontaktfläche 34 zwischen Kühlplatte 30 und Zylinderwandung 15 ausgebildet. Eine Kühlplatte 30 ist entweder einseitig oder beidseitig der offenen Enden des Zylinders 16 angeordnet. Ferner sind die Kühlplatten entsprechend dem Zylinderquerschnitt ringförmig ausgebildet so daß sie auf dem umlaufenden Zylinderwandung 15 aufliegen und in dem Ring eine Öffnung zum Einführen der Beschichtungsvorrichtung 10 zur Verfügung stellen. Die in der Fig. 1 unterer Kühlplatte 30 hat bei ringförmiger Ausführung den weiteren Vorteil, daß Prozeßgase und überschüssiges Beschichtungsmaterial, welches an der Zylinderlaufbahn 14 nicht angeschmolzen ist bzw. nicht anhaftet, in Schwerkraftrichtung in der Fig. 1 nach unten abgeführt werden können.The assembly comprises a cooling plate 30 which is constructed, i. is made by a plate system or mechanically, or cast and includes cooling channels 32, which are traversed by the cooling medium. In this way, the cooling plate is actively cooled and performs on the mere heat conduction also active heat energy. The cooling channels have, for example, a rectangular and / or round cross-section and are in particular formed above a contact surface 34 between the cooling plate 30 and the cylinder wall 15. A cooling plate 30 is arranged either on one side or on both sides of the open ends of the cylinder 16. Further, the cooling plates are annular according to the cylinder cross-section so that they rest on the circumferential cylinder wall 15 and provide an opening for introducing the coating device 10 in the ring. The lower cooling plate 30 in FIG. 1 has the further advantage, in the case of an annular design, that process gases and excess coating material which is not melted or does not adhere to the cylinder bore 14 can be removed downward in the direction of gravity in FIG.

Erfindungsgemäß umfaßt die Anordnung einen Kühldorn 36, welcher entsprechend dem Querschnitt des Zylinders 16 derart ausgebildet ist, daß dieser Kühldorn 36 in den Zylinder 16 einführbar ist und dort in Umfangsrichtung an der Zylinderwandung 15 anliegt. Alternativ oder zusätzlich zum Anliegen des Kühldornes 36 direkt an der Zylinderwandung 15 sind am Mantel des Kühldornes 36 Kühlborsten 38, beispielsweise aus Kupfer, vorgesehen, welche mit der Oberfläche der Zylinderwandung 15 in Kontakt stehen und auf diese Weise Wärme von der Zylinderwandung 15 zum Kühldorn 36 ableiten. In dem Kühldorn sind ferner von einem Kühlmedium durchströmte Kühlkanäle 40 vorgesehen, welche in der vorerwähnten Weise zur aktiven Kühlung und Wärmeenergieabführung dienen. Die Kühlkanäle sind spiralförmig umlaufend ausgebildet.According to the invention, the arrangement comprises a cooling mandrel 36, which is formed according to the cross section of the cylinder 16 such that this cooling mandrel 36 is inserted into the cylinder 16 and abuts there in the circumferential direction of the cylinder wall 15. Alternatively, or in addition to the concern of the cooling mandrel 36 directly to the cylinder wall 15 cooling bristles 38, for example copper, are provided on the jacket of the cooling mandrel 38, which are in contact with the surface of the cylinder wall 15 and in this way heat from the cylinder wall 15 to the cooling mandrel 36 derived. In the cooling mandrel cooling channels 40 are further provided by a cooling medium, which serve in the aforementioned manner for active cooling and heat energy dissipation. The cooling channels are formed spirally encircling.

Mittels eines am in der Fig. 1 unteren Kühldorn 36 ausgebildeten Auffangbeckes 42 werden nicht an der Zylinderwandung 15 haftende Partikel aufgefangen. Zweckmäßigerweise ist auch das Auffangbecken 42 mit Kühlmedium gefülit. Eine zusätzliche Auffangnase 44 leitet überschüssigen, herabfallenden Beschichtungswerkstoff in das Auffangbecken 42. Für das Kühlmedium in dem Auffangbecken 42 und/oder in den Kühlkanälen 40 ist ein Kühlmediumzufluß 46 und ein Kühlmediumabfluß 48 vorgesehen. Erfindungsgemäß wird ein oder werden beide der in Fig. 1 dargestellten Kühldorne 36 in der Vorschubgeschwindigkeit der Beschichtungsvorrichtung in Pfeilrichtung 24 mitgeführt, wie durch Pfeile 50 angedeutet.By means of a collecting bowl 42 formed on the lower cooling mandrel 36 in FIG. 1, particles adhering to the cylinder wall 15 are not collected. Conveniently, the catch basin 42 is gefülit with cooling medium. An additional catch nose 44 directs excess, falling coating material in the catch basin 42. For the cooling medium in the catch basin 42 and / or in the cooling channels 40, a Kühlmediumzufluß 46 and a Kühlmediumabfluß 48 is provided. According to the invention, one or both of the cooling mandrels 36 shown in FIG. 1 are entrained in the direction of arrow 24 at the feed rate of the coating device, as indicated by arrows 50.

Zur Glättung der beschichteten Oberfläche kann zudem ein Honen nach der Beschichtung erfolgen, wobei der Hon-Vorgang je nach gewünschter Oberflächengüte mehrere Schritte umfassen kann.To smooth the coated surface, honing may also take place after the coating, wherein the honing process may comprise several steps depending on the desired surface quality.

In einer bevorzugten Weiterbildung der Erfindung ist es ferner vorgesehen, daß während der Beschichtung der Zylinderlauffläche 14 mit dem Plasmastrahl 12 oder einem Laserstrahl durch den Wasserraum 26 ein Kühlfluid, wie beispielsweise Gas, Stickstoff oder eine Kühlflüssigkeit geleitet wird, welche zu einer weiteren Kühlung der Zylinderwandung 15 führt und somit zusätzlich Wärme aus der Beschichtungszone abführt.In a preferred embodiment of the invention, it is further provided that during the coating of the cylinder surface 14 with the plasma jet 12 or a laser beam through the water chamber 26, a cooling fluid, such as gas, nitrogen or a cooling liquid is passed, resulting in further cooling of the cylinder wall 15 leads and thus additionally dissipates heat from the coating zone.

Claims (13)

  1. Process for producing wear-resistant surfaces on components made from an AlSi alloy, the wear-resistant surfaces being applied by means of thermal spraying or a laser beam, during the production of the wear-resistant surface at least one thermally conductive device being brought into thermally conductive contact with the component, and this thermally conductive device being actively cooled, the component being a crankcase of a reciprocating internal combustion engine, on whose cylinder liners of cylinders the coating is carried out, characterized in that the thermally conductive device comprises at least one cooling mandrel which corresponds to the cross section of the cylinder, bears against the cylinder wall in the circumferential direction and is brought into contact with the cylinder liner trailing a coating zone and/or following the coating zone, as seen in the axial direction of the cylinder.
  2. Process according to Claim 1, characterized in that, after the wear-resistant surface has been formed in the form of a thermally sprayed layer, this layer is additionally treated, in particular remelted, using a laser beam.
  3. Process according to Claim 1 or 2, characterized in that remelting, alloying, dispersing and/or coating is carried out by means of a laser beam or by thermal spraying.
  4. Process according to Claim 1, characterized in that during the production of the wear-resistant surface a water chamber of the crankcase has a cooling medium, in particular gas, nitrogen or a cooling liquid, flowing through it.
  5. Process according to one of the preceding claims, characterized in that the active cooling of the thermally conductive device is carried out using a gas, nitrogen and/or a cooling liquid.
  6. Arrangement for producing wear-resistant surfaces on components made from an AlSi alloy, in particular on cylinder liners (14) of cylinders (16) of a crankcase (18) of a reciprocating internal combustion engine having a thermally conductive device (30, 36, 52), which is arranged in thermally conductive contact with the component (16) and comprises a cooling medium, characterized in that the thermally conductive device comprises at least one cooling mandrel (36) which corresponds to the cross section of a cylinder bore (16), bears against the cylinder wall in the circumferential direction, has passages (40) through which the cooling medium flows and, in the axial direction of the cylinder (16), is arranged on one or both sides of a coating zone (28), in such a manner that thermally conductive contact is formed between the cooling mandrel (36) and the cylinder liner (14).
  7. Arrangement according to Claim 6, characterized in that the cooling medium comprises a gas, nitrogen and/or a cooling liquid.
  8. Arrangement according to Claim 6, characterized in that the passages (40) through which the cooling medium flows are of helically encircling design.
  9. Arrangement according to Claim 6, characterized in that a cooling mandrel (36), which is arranged beneath the coating zone (28) in the direction of the force of gravity, is designed with a collection tank (42) for excess coating material.
  10. Arrangement according to Claim 9, characterized in that a collection lug (44) is formed on a side of the periphery of the cooling mandrel (36) which faces the coating zone (28).
  11. Arrangement according to one of Claims 6 to 10, characterized in that the cooling mandrel (36), on its periphery which faces the cylinder liner (14), is designed with cooling bristles (38) which are in brushing contact with the cylinder liner (14).
  12. Arrangement according to Claim 11, characterized in that the cooling bristles (38) are made from a thermally conductive material, in particular copper.
  13. Process according to Claim 1, characterized in that a honing operation on the surface follows the thermal surface treatment of the component.
EP00902632A 1999-02-19 2000-01-26 Method and system for producing wear-resistant surfaces Expired - Lifetime EP1161569B2 (en)

Applications Claiming Priority (5)

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DE19907104 1999-02-19
DE19907104 1999-02-19
DE19941562 1999-09-01
DE19941562A DE19941562A1 (en) 1999-02-19 1999-09-01 Method and arrangement for producing wear-resistant surfaces
PCT/EP2000/000575 WO2000049194A1 (en) 1999-02-19 2000-01-26 Method and system for producing wear-resistant surfaces

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EP1161569A1 EP1161569A1 (en) 2001-12-12
EP1161569B1 EP1161569B1 (en) 2002-12-18
EP1161569B2 true EP1161569B2 (en) 2006-02-08

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EP (1) EP1161569B2 (en)
JP (1) JP2002537487A (en)
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DE102011106564A1 (en) * 2011-07-05 2013-01-10 Mahle International Gmbh Method for producing a cylinder surface and cylinder liner
JP5880572B2 (en) 2011-11-22 2016-03-09 日産自動車株式会社 Cylinder block manufacturing method
WO2015068519A1 (en) * 2013-11-05 2015-05-14 日産自動車株式会社 Spray coating forming device and spray coating forming method
CN105331972A (en) * 2015-09-24 2016-02-17 安庆市灵宝机械有限责任公司 Method for manufacturing wear-resisting coating for wear-resisting coal cutting tooth
CN105177567A (en) * 2015-09-24 2015-12-23 安庆市灵宝机械有限责任公司 Preparation method of wear-resistant coating on surface of steel base
CN105543838A (en) * 2015-12-25 2016-05-04 燕山大学 Remanufacturing method for marine crankshaft
US11915850B2 (en) 2017-12-20 2024-02-27 Applied Materials, Inc. Two channel cosine-theta coil assembly
CN110735102B (en) * 2019-11-15 2024-01-26 天宜上佳（天津）新材料有限公司 Brake disc production method and brake disc cooling device

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WO2000049194A1 (en) 2000-08-24
CN1153844C (en) 2004-06-16
US6634179B2 (en) 2003-10-21
JP2002537487A (en) 2002-11-05
US20020012753A1 (en) 2002-01-31
CN1341156A (en) 2002-03-20
EP1161569A1 (en) 2001-12-12
EP1161569B1 (en) 2002-12-18

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