EP2110465B1 - Method for manufacturing a metallic part and metallic part - Google Patents

Method for manufacturing a metallic part and metallic part Download PDF

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Publication number
EP2110465B1
EP2110465B1 EP09157727.0A EP09157727A EP2110465B1 EP 2110465 B1 EP2110465 B1 EP 2110465B1 EP 09157727 A EP09157727 A EP 09157727A EP 2110465 B1 EP2110465 B1 EP 2110465B1
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EP
European Patent Office
Prior art keywords
base body
aluminum
coating
component
cast
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EP09157727.0A
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German (de)
French (fr)
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EP2110465A2 (en
EP2110465A3 (en
Inventor
Dr. Stephan Beer
Jürgen Niehues
Dr. Herbert Möding
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KS Huayu Alutech GmbH
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KS Huayu Alutech GmbH
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    • C—CHEMISTRY; METALLURGY
    • C25—ELECTROLYTIC OR ELECTROPHORETIC PROCESSES; APPARATUS THEREFOR
    • C25D—PROCESSES FOR THE ELECTROLYTIC OR ELECTROPHORETIC PRODUCTION OF COATINGS; ELECTROFORMING; APPARATUS THEREFOR
    • C25D5/00—Electroplating characterised by the process; Pretreatment or after-treatment of workpieces
    • C25D5/10—Electroplating with more than one layer of the same or of different metals
    • C25D5/12—Electroplating with more than one layer of the same or of different metals at least one layer being of nickel or chromium
    • 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
    • B22D19/0081—Casting in, on, or around objects which form part of the product pretreatment of the insert, e.g. for enhancing the bonding between insert and surrounding cast metal
    • C—CHEMISTRY; METALLURGY
    • C25—ELECTROLYTIC OR ELECTROPHORETIC PROCESSES; APPARATUS THEREFOR
    • C25D—PROCESSES FOR THE ELECTROLYTIC OR ELECTROPHORETIC PRODUCTION OF COATINGS; ELECTROFORMING; APPARATUS THEREFOR
    • C25D5/00—Electroplating characterised by the process; Pretreatment or after-treatment of workpieces
    • C25D5/34—Pretreatment of metallic surfaces to be electroplated
    • C25D5/36—Pretreatment of metallic surfaces to be electroplated of iron or steel
    • C—CHEMISTRY; METALLURGY
    • C25—ELECTROLYTIC OR ELECTROPHORETIC PROCESSES; APPARATUS THEREFOR
    • C25D—PROCESSES FOR THE ELECTROLYTIC OR ELECTROPHORETIC PRODUCTION OF COATINGS; ELECTROFORMING; APPARATUS THEREFOR
    • C25D5/00—Electroplating characterised by the process; Pretreatment or after-treatment of workpieces
    • C25D5/48—After-treatment of electroplated surfaces
    • C—CHEMISTRY; METALLURGY
    • C25—ELECTROLYTIC OR ELECTROPHORETIC PROCESSES; APPARATUS THEREFOR
    • C25D—PROCESSES FOR THE ELECTROLYTIC OR ELECTROPHORETIC PRODUCTION OF COATINGS; ELECTROFORMING; APPARATUS THEREFOR
    • C25D7/00—Electroplating characterised by the article coated
    • C25D7/04—Tubes; Rings; Hollow bodies
    • 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 
    • C—CHEMISTRY; METALLURGY
    • C25—ELECTROLYTIC OR ELECTROPHORETIC PROCESSES; APPARATUS THEREFOR
    • C25D—PROCESSES FOR THE ELECTROLYTIC OR ELECTROPHORETIC PRODUCTION OF COATINGS; ELECTROFORMING; APPARATUS THEREFOR
    • C25D3/00—Electroplating: Baths therefor
    • C25D3/02—Electroplating: Baths therefor from solutions
    • C25D3/42—Electroplating: Baths therefor from solutions of light metals
    • C25D3/44—Aluminium

Definitions

  • the invention relates to a method for producing a metallic component, in which a base body is provided with an aluminum coating and the coated base body is cast with an aluminum alloy, and a component with a base body, on the outer surface of which an aluminum layer is formed, the base body having a Cast aluminum alloy.
  • the coatings of the base body to be cast in serve a better adhesion of the base body to the surrounding casting.
  • cast cylinder liners which form the running surfaces for the cylinders, or to slide bearings in aluminum cylinder crankcases.
  • the cylinder liners are made, for example, from a heavy-duty iron-based alloy, such as lamellar gray cast iron.
  • the layers can be applied, for example, by finishing or thermal spraying.
  • the JP 59-030465 proposed to first coat a cast iron bushing with nickel or copper and then pour it into an aluminum crankcase. This should result in a fusion of the surface coating with the aluminum alloy.
  • an adhesion-promoting layer on a cast body which can be, for example, a cylinder liner made of gray cast iron.
  • the adhesion promoter layer consists of galvanically applied light metal, which is metallurgically bonded to the cast body by means of diffusion annealing.
  • a cylinder liner which is thermally coated from the outside by spraying.
  • at least two axially superimposed different layers are applied.
  • a layer with good heat conductivity is applied in the upper area, while the lower section is provided with a layer with poor heat conductivity. This is intended to improve the connection to the base body when the socket is cast around.
  • the bond between the bonding layer and the cast material is improved compared to a purely mechanical clamping, but the problem of the bond between the cylinder liner and the bonding layer remains, since in this area no metallurgical bond is produced, but only a mechanical one Parenthesis exists.
  • This object is achieved according to the invention by a method in which the aluminum coating is applied galvanically to the base body, the surface of which has a clamping structure with undercuts, and that a nickel coating is applied to the base body before the aluminum coating is applied galvanically, and by a coating produced in this way Component in which the surface of the base body has a clamping structure with undercuts and a galvanically applied nickel coating. This ensures that the aluminum coating deposited on the base body forms a strong metallurgical bond with the cast aluminum alloy and that the aluminum coating is bonded well to the base body.
  • undercut structures can also be coated uniformly and completely, for example base bodies with clamping structures or rough cast bushings which are difficult to access in spraying processes. It has been found that the bond between nickel and gray cast iron, for example, is more stable than the bond between aluminum and gray cast iron. In addition, the bond between the aluminum coating and the nickel layer is also more stable and better, so that overall the strength of the connection to the socket is increased.
  • the aluminum coating can advantageously be an aluminum-based alloy coating. This enables the melting point of the aluminum layer to be reduced during the subsequent encapsulation, so that the bond is improved again.
  • the aluminum coating is applied with a thickness in the range from 5 to 100 ⁇ m, preferably from 10 to 60 ⁇ m and in particular from 20 to 40 ⁇ m. In experiments, such layer thicknesses have been found to be sufficient to improve the bond both to the casting material and to the base body.
  • the coated base body is cast around with an aluminum-based alloy.
  • an AlSi9CU3 alloy can be used here.
  • the base body can advantageously be cleaned prior to the galvanic application of the aluminum coating to the base body. This can be done mechanically, in particular by blasting and / or chemically, in particular by applying a flux. This additionally improves the adhesion of the coating to the base body.
  • undercut structures can be coated evenly and completely, for example base bodies with clamping structures or rough cast bushings.
  • the base body is preferably produced from an iron-based alloy, in particular from lamellar gray cast iron (GGL).
  • GGL lamellar gray cast iron
  • the nickel coating is preferably applied to the base body with a thickness> 5 ⁇ m, in particular in the range between 1 and 2 ⁇ m. It has been found that the bond between nickel and gray cast iron, for example, is more stable than the bond between aluminum and gray cast iron. In addition, the bond between the aluminum coating and the nickel layer is also more stable and better, so that overall the strength of the connection to the socket is increased.
  • the component is preferably a cylinder crankcase or a cylinder crankcase lower part, which is also referred to as a bearing crossmember or bedplate.
  • the method according to the invention can be used particularly advantageously for these components.
  • the base body is a cylinder liner. This makes it possible to use heavy-duty cylinder liners in aluminum crankcases have low weight, to create and to fix the socket so that loosening is reliably prevented.
  • a micrograph of a component produced by the method according to the invention is shown in the figure.
  • the component 1 shown consists of a base body 2 in the form of a cast iron cylinder liner, which was first chemically cleaned using a flux. A nickel layer 3 was then applied galvanically to the cleaned surface. The thickness of this nickel layer 3 is approximately 5 ⁇ m. An aluminum layer 4 with a thickness of approximately 25 ⁇ m was then applied galvanically to this nickel layer 3 in a galvanic bath. The cylinder liner 2 prepared in this way was then cast with an aluminum-silicon alloy 5 made of AlSi9CU3 in a die-casting process to produce a cylinder crankcase 1.
  • a component was created that is also suitable for use in high-performance motors with high thermal and mechanical loads. A loosening of the socket in the casting can be excluded.

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Electrochemistry (AREA)
  • Materials Engineering (AREA)
  • Metallurgy (AREA)
  • Organic Chemistry (AREA)
  • Mechanical Engineering (AREA)
  • Combustion & Propulsion (AREA)
  • General Engineering & Computer Science (AREA)
  • Cylinder Crankcases Of Internal Combustion Engines (AREA)
  • Pistons, Piston Rings, And Cylinders (AREA)
  • Other Surface Treatments For Metallic Materials (AREA)
  • Electroplating Methods And Accessories (AREA)

Description

Die Erfindung betrifft ein Verfahren zur Herstellung eines metallischen Bauteils, bei dem ein Grundkörper mit einer Aluminiumbeschichtung versehen und der beschichtete Grundkörper mit einer Aluminiumlegierung umgossen wird, sowie ein Bauteil mit einem Grundkörper, auf dessen äußerer Oberfläche eine Aluminiumschicht ausgebildet ist, wobei der Grundkörper mit einer Aluminiumlegierung umgossen ist.The invention relates to a method for producing a metallic component, in which a base body is provided with an aluminum coating and the coated base body is cast with an aluminum alloy, and a component with a base body, on the outer surface of which an aluminum layer is formed, the base body having a Cast aluminum alloy.

Derartige Bauteile und Verfahren sind bekannt. Die Beschichtungen der einzugießenden Grundkörper dienen dabei einer besseren Haftung des Grundkörpers am umgebenden Guss. Insbesondere beim Aluminiumguss ist es häufig notwendig, an hochbelasteten Flächen einzugießende Teile vorzusehen, um Oberflächen zu schaffen, durch deren Härte eine zu große Abnutzung durch die Bewegung entlang der Oberfläche vermieden wird. So ist es beispielsweise bekannt, Zylinderbuchsen, die die Laufflächen für die Zylinder bilden oder Gleitlager in Zylinderkurbelgehäuse aus Aluminium einzugießen. Die Zylinderlaufbuchsen sind beispielsweise aus einer hoch belastbaren Eisenbasislegierung, wie lamellarem Grauguss, hergestellt. Das Aufbringen der Schichten kann beispielsweise durch Alfinieren oder thermisches Spritzen erfolgen.Such components and methods are known. The coatings of the base body to be cast in serve a better adhesion of the base body to the surrounding casting. In the case of aluminum casting in particular, it is often necessary to provide parts to be cast in on heavily loaded surfaces in order to create surfaces whose hardness prevents excessive wear due to the movement along the surface. For example, it is known to cast cylinder liners, which form the running surfaces for the cylinders, or to slide bearings in aluminum cylinder crankcases. The cylinder liners are made, for example, from a heavy-duty iron-based alloy, such as lamellar gray cast iron. The layers can be applied, for example, by finishing or thermal spraying.

Um die Anbindung solcher Zylinderlaufbuchsen an den umgebenden Guss zu verbessern, wird in der JP 59-030465 vorgeschlagen, eine Gusseisenbuchse zunächst mit Nickel oder Kupfer zu beschichten und anschließend in ein Aluminiumkurbelgehäuse einzugießen. Hierbei soll eine Verschmelzung der Oberflächenbeschichtung mit der Aluminiumlegierung entstehen.In order to improve the connection of such cylinder liners to the surrounding casting, the JP 59-030465 proposed to first coat a cast iron bushing with nickel or copper and then pour it into an aluminum crankcase. This should result in a fusion of the surface coating with the aluminum alloy.

Aus der EP 1 124 660 B1 ist es bekannt, eine Zylinderlaufbuchse durch thermisches Spritzen mit einer Aluminium-Silizium-Legierung zu beschichten. Durch diese Beschichtung der Laufbuchse wird eine poröse Oberfläche geschaffen, welche beim Umgießen dazu führen soll, dass die Oxidhaut immer wieder aufreißt, so dass ein direkter Kontakt zwischen Schmelze und Oberfläche der Anbindeschicht stattfindet. Die Schmelze infiltriert daraufhin die Anbindeschicht und schmilzt diese an der Oberfläche auf, wodurch eine stoffschlüssige Verbindung erreicht werden soll. Somit wird eine hohe Festigkeit zwischen der Anbindeschicht und dem Umgusswerkstoff erreicht.From the EP 1 124 660 B1 it is known to coat a cylinder liner by thermal spraying with an aluminum-silicon alloy. This coating of the liner creates a porous surface which, when cast, should cause the oxide skin to tear open again and again, so that there is direct contact between the melt and the surface the tie layer takes place. The melt then infiltrates the bonding layer and melts it on the surface, whereby a material connection is to be achieved. This ensures high strength between the bonding layer and the encapsulation material.

Des Weiteren Ist aus der EP 1 688 517 A1 ein Verfahren zur Herstellung einer Haftvermittlungsschicht auf einen Umgusskörper bekannt, der beispielswelse eine Zylinderlaufbuchse aus Grauguss sein kann. Die Haftvermittlerschicht besteht dabei aus galvanisch aufgebrachtem Leichtmetall, welches mittels Diffusionsglühen metallurgisch an den Umgusskörper angebunden wird.Furthermore, from the EP 1 688 517 A1 a method for producing an adhesion-promoting layer on a cast body is known, which can be, for example, a cylinder liner made of gray cast iron. The adhesion promoter layer consists of galvanically applied light metal, which is metallurgically bonded to the cast body by means of diffusion annealing.

Aus der US 2007/0012175 A1 ist eine Zylinderlaufbuchse bekannt, die von außen thermisch durch Spritzen beschichtet wird. Hierbei werden mindestens zwei axial übereinanderliegende unterschiedliche Schichten aufgebracht. Im oberen Bereich wird eine gut Wärme leitende Schicht aufgebracht, während der untere Abschnitt mit einer schlecht Wärme leitenden Schicht versehen wird. Hierdurch soll die Anbindung an den Grundkörper beim Umgießen der Buchse verbessert werden.From the US 2007/0012175 A1 a cylinder liner is known which is thermally coated from the outside by spraying. Here, at least two axially superimposed different layers are applied. A layer with good heat conductivity is applied in the upper area, while the lower section is provided with a layer with poor heat conductivity. This is intended to improve the connection to the base body when the socket is cast around.

Schließlich ist aus der US 4,925,536 ein Verfahren zur Metallbeschichtung von Metallwerkstoffen, insbesondere niedriglegierten hochfesten Stählen, bekannt, bei dem aus nichtwässrigen Elektrolyten galvanisch Haftvermittlungsschichten aus Eisen, Eisen und Nickel, Nickel, Cobalt, Kupfer oder Legierungen der vorstehend genannten Metalle auf diese Metallwerkstoffe abgeschieden und darauf dann anschließend galvanisch Aluminium abgeschieden wird.After all, is out of US 4,925,536 a process for the metal coating of metal materials, in particular low-alloy high-strength steels, is known in which, from non-aqueous electrolytes, adhesion-promoting layers of iron, iron and nickel, nickel, cobalt, copper or alloys of the above-mentioned metals are deposited onto these metal materials and then subsequently galvanically deposited aluminum becomes.

Auch ist es aus der EP 0 919 715 A2 bekannt, vor dem Umgießen einer Zylinderlaufbuchse mit Aluminium, die Buchse an ihrer Außenseite mit Hinterschnitten zu versehen.It is also out of the EP 0 919 715 A2 known to provide the socket on its outside with undercuts before casting a cylinder liner with aluminum.

Bei den bekannten Verfahren wird zwar die Bindung zwischen Anbindeschicht und dem Gusswerkstoff im Vergleich zu einer rein mechanischen Verklammerung verbessert, jedoch bleibt das Problem der Anbindung zwischen der Zylinderbuchse und der Anbindeschicht, da in diesem Bereich keine metallurgische Bindung erzeugt wird, sondern weiterhin lediglich eine mechanische Verklammerung besteht.In the known methods, the bond between the bonding layer and the cast material is improved compared to a purely mechanical clamping, but the problem of the bond between the cylinder liner and the bonding layer remains, since in this area no metallurgical bond is produced, but only a mechanical one Parenthesis exists.

Es ist daher Aufgabe der vorliegenden Erfindung, ein Verfahren zur Herstellung eines metallischen Bauteils sowie ein derartig hergestelltes Bauteil bereitzustellen, bei denen die Anbindung zwischen der Beschichtung und der Zylinderbuchse und damit die Haltbarkeit des Grundkörpers im Gussteil verbessert wird.It is therefore an object of the present invention to provide a method for producing a metallic component and a component produced in this way, in which the connection between the coating and the cylinder liner and thus the durability of the base body in the cast part are improved.

Diese Aufgabe wird erfindungsgemäß durch ein Verfahren gelöst, bei dem die Aluminiumbeschichtung galvanisch auf den Grundkörper aufgebracht wird, dessen Oberfläche eine Verklammerungsstruktur mit Hinterschnitten aufweist, und dass auf den Grundkörper vor dem galvanischen Aufbringen der Aluminiumbeschichtung galvanisch eine Nickelbeschichtung aufgebracht wird, sowie durch ein derartig hergestelltes Bauteil, bei dem die Oberfläche des Grundkörpers eine Verklammerungsstruktur mit Hinterschnitten und eine galvanisch aufgebrachte Nickelbeschichtung aufweist. Hierdurch wird erreicht, dass die auf dem Grundkörper abgeschiedene Aluminiumbeschichtung mit der Aluminium-Gusslegierung eine starke metallurgische Bindung eingeht und eine gute Bindung der Aluminiumbeschichtung zum Grundkörper hergestellt wird. Diese wird neben der stärkeren Bindung beim Beschichten durch Galvanisieren auch dadurch erreicht, dass auch Hinterschnittstrukturen gleichmäßig und vollständig beschichtet werden können, zum Beispiel Grundkörper mit Verklammerungsstrukturen oder Raugussbuchsen, welche in Spritzverfahren schwer zugänglich sind. Es hat sich herausgestellt, dass die Bindung von Nickel beispielsweise zum Grauguss beständiger ist als die Bindung zwischen Aluminium und Grauguss. Zusätzlich ist auch die Bindung zwischen der Aluminiumbeschichtung und der Nickelschicht beständiger und besser, so dass insgesamt die Festigkeit der Verbindung zur Buchse erhöht wird.This object is achieved according to the invention by a method in which the aluminum coating is applied galvanically to the base body, the surface of which has a clamping structure with undercuts, and that a nickel coating is applied to the base body before the aluminum coating is applied galvanically, and by a coating produced in this way Component in which the surface of the base body has a clamping structure with undercuts and a galvanically applied nickel coating. This ensures that the aluminum coating deposited on the base body forms a strong metallurgical bond with the cast aluminum alloy and that the aluminum coating is bonded well to the base body. In addition to the stronger bond during coating by electroplating, this is also achieved by the fact that undercut structures can also be coated uniformly and completely, for example base bodies with clamping structures or rough cast bushings which are difficult to access in spraying processes. It has been found that the bond between nickel and gray cast iron, for example, is more stable than the bond between aluminum and gray cast iron. In addition, the bond between the aluminum coating and the nickel layer is also more stable and better, so that overall the strength of the connection to the socket is increased.

Die Aluminiumbeschichtung kann dabei vorteilhafterweise eine Aluminium-Basis-Legierungsbeschichtung sein. Dies ermöglicht die Verringerung des Schmelzpunktes der Aluminiumschicht beim anschließenden Umgießen, so dass die Bindung erneut verbessert wird.The aluminum coating can advantageously be an aluminum-based alloy coating. This enables the melting point of the aluminum layer to be reduced during the subsequent encapsulation, so that the bond is improved again.

Gemäß einer ersten Ausführungsform der Erfindung ist vorgesehen, die Aluminiumbeschichtung mit einer Dicke im Bereich von 5 bis 100 µm, bevorzugt von 10 bis 60 µm und insbesondere von 20 bis 40 µm aufzubringen. Derartige Schichtdicken haben sich in Versuchen als ausreichend zur Verbesserung der Bindung sowohl zum Umgusswerkstoff als auch zum Grundkörper erwiesen.According to a first embodiment of the invention, the aluminum coating is applied with a thickness in the range from 5 to 100 μm, preferably from 10 to 60 μm and in particular from 20 to 40 μm. In experiments, such layer thicknesses have been found to be sufficient to improve the bond both to the casting material and to the base body.

In Weiterbildung der Erfindung ist vorgesehen, dass der beschichtete Grundkörper mit einer Aluminium-Basis-Legierung umgegossen wird. Hier kann insbesondere eine AlSi9CU3-Legierung verwendet werden.In a further development of the invention, it is provided that the coated base body is cast around with an aluminum-based alloy. In particular, an AlSi9CU3 alloy can be used here.

Vorteilhafterweise kann der Grundkörper vor dem galvanischen Aufbringen der Aluminiumbeschichtung auf den Grundkörper gereinigt werden. Dies kann mechanisch, insbesondere durch Strahlen und/oder chemisch, insbesondere durch Auftragen eines Flussmittels erfolgen. Hierdurch wird die Haftung der Beschichtung am Grundkörper zusätzlich verbessert.The base body can advantageously be cleaned prior to the galvanic application of the aluminum coating to the base body. This can be done mechanically, in particular by blasting and / or chemically, in particular by applying a flux. This additionally improves the adhesion of the coating to the base body.

Ein weiterer signifikanter Vorteil der galvanischen Schichtabscheidung gegenüber Spritzverfahren liegt darin, dass Hinterschnittstrukturen gleichmäßig und vollständig beschichtet werden können, zum Beispiel Grundkörper mit Verklammerungsstrukturen oder Raugussbuchsen.Another significant advantage of galvanic layer deposition compared to spray processes is that undercut structures can be coated evenly and completely, for example base bodies with clamping structures or rough cast bushings.

Vorzugsweise wird der Grundkörper aus einer Eisenbasislegierung, insbesondere aus lamellarem Grauguss (GGL), hergestellt. Dieser weist eine mechanisch hoch belastbare Oberfläche auf, die beispielsweise als Zylinderlauffläche in einem Verbrennungsmotor geeignet ist.The base body is preferably produced from an iron-based alloy, in particular from lamellar gray cast iron (GGL). This has a mechanically highly resilient surface, which is suitable, for example, as a cylinder running surface in an internal combustion engine.

Vorzugsweise wird die Nickelbeschichtung mit einer Dicke > 5 µm insbesondere im Bereich zwischen 1 bis 2 µm auf den Grundkörper aufgebracht. Es hat sich herausgestellt, dass die Bindung von Nickel beispielsweise zum Grauguss beständiger ist als die Bindung zwischen Aluminium und Grauguss. Zusätzlich ist auch die Bindung zwischen der Aluminiumbeschichtung und der Nickelschicht beständiger und besser, so dass insgesamt die Festigkeit der Verbindung zur Buchse erhöht wird.The nickel coating is preferably applied to the base body with a thickness> 5 μm, in particular in the range between 1 and 2 μm. It has been found that the bond between nickel and gray cast iron, for example, is more stable than the bond between aluminum and gray cast iron. In addition, the bond between the aluminum coating and the nickel layer is also more stable and better, so that overall the strength of the connection to the socket is increased.

Vorzugsweise ist das Bauteil ein Zylinderkurbelgehäuse oder ein Zylinderkurbelgehäuseunterteil, welches auch als Lagertraverse oder Bedplate bezeichnet wird. Für diese Bauteile lässt sich das erfindungsgemäße Verfahren besonders vorteilhaft einsetzen.The component is preferably a cylinder crankcase or a cylinder crankcase lower part, which is also referred to as a bearing crossmember or bedplate. The method according to the invention can be used particularly advantageously for these components.

Insbesondere ist der Grundkörper eine Zylinderlaufbuchse. So wird es möglich, hoch belastbare Zylinderlaufflächen in Aluminiumkurbelgehäusen, die ein geringes Gewicht aufweisen, zu schaffen und die Buchse so zu befestigen, dass ein Lösen zuverlässig unterbunden wird.In particular, the base body is a cylinder liner. This makes it possible to use heavy-duty cylinder liners in aluminum crankcases have low weight, to create and to fix the socket so that loosening is reliably prevented.

Ein Schliffbild eines nach dem erfindungsgemäßen Verfahren hergestellten Bauteils ist in der Figur dargestellt.A micrograph of a component produced by the method according to the invention is shown in the figure.

Das dargestellte Bauteil 1 besteht aus einem Grundkörper 2 in Form einer Grauguss-Zylinderbuchse, welche zunächst chemisch mittels eines Flussmittels gereinigt wurde. Auf die gereinigte Oberfläche wurde anschließend galvanisch eine Nickelschicht 3 aufgetragen. Die Dicke dieser Nickelschicht 3 beträgt etwa 5µm. Auf diese Nickelschicht 3 wurde anschließend wiederum galvanisch in einem Galvanikbad eine Aluminiumschicht 4 in einer Dicke von etwa 25µm aufgebracht. Die so vorbereitete Zylinderbuchse 2 wurde anschließend mit einer Aluminium-Silizium-Legierung 5 aus AlSi9CU3 im Druckgussverfahren zur Herstellung eines Zylinderkurbelgehäuses 1 umgossen.The component 1 shown consists of a base body 2 in the form of a cast iron cylinder liner, which was first chemically cleaned using a flux. A nickel layer 3 was then applied galvanically to the cleaned surface. The thickness of this nickel layer 3 is approximately 5 μm. An aluminum layer 4 with a thickness of approximately 25 μm was then applied galvanically to this nickel layer 3 in a galvanic bath. The cylinder liner 2 prepared in this way was then cast with an aluminum-silicon alloy 5 made of AlSi9CU3 in a die-casting process to produce a cylinder crankcase 1.

Es zeigte sich zwischen allen Schichten eine sehr gute Haftung. Fehlstellen durch Oxidbildung oder dergleichen sind durch die Verwendung des erfindungsgemäßen Verfahrens fast vollständig unterbunden worden.There was very good adhesion between all layers. Defects due to oxide formation or the like have been almost completely prevented by using the method according to the invention.

Entsprechend wurde ein Bauteil geschaffen, welches auch für den Einsatz in Hochleistungsmotoren mit hohen thermischen und mechanischen Belastungen geeignet ist. Ein Lösen der Buchse im Umguss kann ausgeschlossen werden.Accordingly, a component was created that is also suitable for use in high-performance motors with high thermal and mechanical loads. A loosening of the socket in the casting can be excluded.

Claims (12)

  1. Method for producing a metallic component (1), in which a base body (2) is provided with an aluminum coating (4) and an aluminum alloy is cast around the coated base body (2), characterized in that the aluminum coating (4) is applied galvanically to the base body (2), the surface of the base body (2) comprising a clamping structure with undercuts, and in that a nickel coating (3) is applied galvanically to the base body (2) prior to the galvanic application of the aluminum coating (4).
  2. Method of claim 1, characterized in that the aluminum coating (4) is an aluminum-based alloy coating.
  3. Method of claim 1 or 2, characterized in that the aluminum coating (4) is applied with a thickness in the range from 5 to 100 µm, preferably from 10 to 60 µm and in particular from 20 to 40 µm.
  4. Method of one of the preceding claims, characterized in that an aluminum-based alloy (5) is cast around the coated base body (2).
  5. Method of one of the preceding claims, characterized in that the base body (2) is cleaned prior to the galvanic application of the aluminum coating (4) to the base body (2).
  6. Method of claim 5, characterized in that the base body (2) is cleaned mechanically in particular by blasting and/or chemically in particular by applying a flux.
  7. Method of one of the preceding claims, characterized in that the base body (2) is made from an iron-based alloy, in particular from lamellar gray cast iron (GGL).
  8. Method of one of the preceding claims, characterized in that the nickel coating (3) is applied to the base body (2) with a thickness >5 µm.
  9. Method of one of the preceding claims, characterized in that the nickel coating is applied to the base body (2) with a thickness in the range between 1 and 2 µm.
  10. Component comprising a base body (2), on the outer surface of which an aluminum layer (4) is formed, an aluminum alloy being cast around the base body (2), characterized in that the surface of the base body (2) comprises a clamping structure with undercuts and a nickel coating (3) applied galvanically and in that the component (1) is made according to a method according to one of claims 1 to 9.
  11. Component of claim 10, characterized in that the component (1) is a cylinder crankcase or a cylinder crankcase lower part.
  12. Component of claim 11, characterized in that the base body (2) is a cylinder liner.
EP09157727.0A 2008-04-17 2009-04-09 Method for manufacturing a metallic part and metallic part Active EP2110465B1 (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
DE102008019206 2008-04-17
DE102008048109.2A DE102008048109B4 (en) 2008-04-17 2008-09-19 Method for producing a metallic component and use of a cylinder part as basic body for carrying out the method

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EP2110465A2 EP2110465A2 (en) 2009-10-21
EP2110465A3 EP2110465A3 (en) 2015-08-19
EP2110465B1 true EP2110465B1 (en) 2020-04-29

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DE (1) DE102008048109B4 (en)
ES (1) ES2798004T3 (en)
HU (1) HUE050304T2 (en)

Families Citing this family (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE102010055162A1 (en) * 2010-12-18 2012-06-21 Mahle International Gmbh Coating and coated casting component
BR102014022261A2 (en) * 2014-09-09 2016-04-26 Mahle Int Gmbh cylinder liner for engagement in an engine block and engine block
DE102020205456A1 (en) 2020-04-29 2021-11-04 Volkswagen Aktiengesellschaft Method, device and computer program for generating quality information about a coating profile, method, device and computer program for generating a database, monitoring device

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US4154900A (en) * 1976-05-14 1979-05-15 Taiho Kogyo Co., Ltd. Composite material of ferrous cladding material and aluminum cast matrix and method for producing the same
DE19750687A1 (en) * 1997-11-15 1999-05-20 Ks Aluminium Technologie Ag Method for casting in inserted parts
EP0919715A2 (en) * 1997-12-01 1999-06-02 KS Aluminium Technologie Aktiengesellschaft Cylinder liner
EP1308227A1 (en) * 2001-10-31 2003-05-07 DaimlerChrysler AG Process for insert moulding a metallic insert

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JPS5741875A (en) * 1980-08-25 1982-03-09 Mazda Motor Corp Production of piston made of aluminum alloy
JPS5930465A (en) 1982-08-12 1984-02-18 Yanmar Diesel Engine Co Ltd Method for embedding ferrous material by casting with aluminum alloy
DE3804303A1 (en) * 1988-02-12 1989-08-24 Studiengesellschaft Kohle Mbh METHOD FOR ADMINISTERING BETWEEN METAL MATERIALS AND GLAVAN ALUMINUM LAYERS AND NON-AQUE ELECTROLYTE USED THEREOF
DE19937934A1 (en) 1999-08-11 2001-02-15 Bayerische Motoren Werke Ag Cylinder crankcase, method for manufacturing the cylinder liners therefor and method for manufacturing the cylinder crankcase with these cylinder liners
WO2003078676A1 (en) * 2002-03-18 2003-09-25 Karl Merz Method and device for the alfin processing of components
DE502005010834D1 (en) * 2005-02-03 2011-02-24 Ford Werke Gmbh Process for producing a metallic adhesion-promoting layer on a casting
JP4512002B2 (en) * 2005-07-08 2010-07-28 トヨタ自動車株式会社 Cylinder liner

Patent Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4154900A (en) * 1976-05-14 1979-05-15 Taiho Kogyo Co., Ltd. Composite material of ferrous cladding material and aluminum cast matrix and method for producing the same
DE19750687A1 (en) * 1997-11-15 1999-05-20 Ks Aluminium Technologie Ag Method for casting in inserted parts
EP0919715A2 (en) * 1997-12-01 1999-06-02 KS Aluminium Technologie Aktiengesellschaft Cylinder liner
EP1308227A1 (en) * 2001-10-31 2003-05-07 DaimlerChrysler AG Process for insert moulding a metallic insert

Also Published As

Publication number Publication date
ES2798004T3 (en) 2020-12-04
HUE050304T2 (en) 2020-11-30
EP2110465A2 (en) 2009-10-21
EP2110465A3 (en) 2015-08-19
DE102008048109A1 (en) 2009-10-22
DE102008048109B4 (en) 2015-01-29

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