EP2184120B1 - Moulded steel piston for combustion engines - Google Patents
Moulded steel piston for combustion engines Download PDFInfo
- Publication number
- EP2184120B1 EP2184120B1 EP09014391A EP09014391A EP2184120B1 EP 2184120 B1 EP2184120 B1 EP 2184120B1 EP 09014391 A EP09014391 A EP 09014391A EP 09014391 A EP09014391 A EP 09014391A EP 2184120 B1 EP2184120 B1 EP 2184120B1
- Authority
- EP
- European Patent Office
- Prior art keywords
- steel
- piston
- cast
- casting
- annular wall
- 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.)
- Ceased
Links
- 229910000831 Steel Inorganic materials 0.000 title claims description 92
- 239000010959 steel Substances 0.000 title claims description 92
- 238000002485 combustion reaction Methods 0.000 title claims description 18
- 238000005266 casting Methods 0.000 claims description 49
- 238000001816 cooling Methods 0.000 claims description 27
- 239000000463 material Substances 0.000 claims description 25
- 238000000034 method Methods 0.000 claims description 15
- 239000000203 mixture Substances 0.000 claims description 11
- 238000004519 manufacturing process Methods 0.000 claims description 10
- 229910001256 stainless steel alloy Inorganic materials 0.000 claims description 9
- 229910052751 metal Inorganic materials 0.000 claims description 8
- 239000002184 metal Substances 0.000 claims description 8
- 239000004576 sand Substances 0.000 claims description 8
- 238000003466 welding Methods 0.000 claims description 7
- 239000012535 impurity Substances 0.000 claims description 5
- 239000000161 steel melt Substances 0.000 claims description 2
- 230000001174 ascending effect Effects 0.000 claims 1
- 229910052804 chromium Inorganic materials 0.000 description 6
- 238000005304 joining Methods 0.000 description 6
- 229910001208 Crucible steel Inorganic materials 0.000 description 5
- 229910052748 manganese Inorganic materials 0.000 description 5
- 229910052802 copper Inorganic materials 0.000 description 4
- 239000000155 melt Substances 0.000 description 4
- 229910052759 nickel Inorganic materials 0.000 description 4
- 229910052758 niobium Inorganic materials 0.000 description 4
- 229910045601 alloy Inorganic materials 0.000 description 3
- 239000000956 alloy Substances 0.000 description 3
- 229910052782 aluminium Inorganic materials 0.000 description 3
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 description 3
- 229910000851 Alloy steel Inorganic materials 0.000 description 2
- IJGRMHOSHXDMSA-UHFFFAOYSA-N Atomic nitrogen Chemical compound N#N IJGRMHOSHXDMSA-UHFFFAOYSA-N 0.000 description 2
- 230000005484 gravity Effects 0.000 description 2
- 238000007711 solidification Methods 0.000 description 2
- 230000008023 solidification Effects 0.000 description 2
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 description 1
- 238000000576 coating method Methods 0.000 description 1
- 239000002826 coolant Substances 0.000 description 1
- 230000007797 corrosion Effects 0.000 description 1
- 238000005260 corrosion Methods 0.000 description 1
- 230000007547 defect Effects 0.000 description 1
- 230000001419 dependent effect Effects 0.000 description 1
- 238000005553 drilling Methods 0.000 description 1
- 238000005516 engineering process Methods 0.000 description 1
- 239000007789 gas Substances 0.000 description 1
- 229910002804 graphite Inorganic materials 0.000 description 1
- 239000010439 graphite Substances 0.000 description 1
- 239000011261 inert gas Substances 0.000 description 1
- 238000003780 insertion Methods 0.000 description 1
- 230000037431 insertion Effects 0.000 description 1
- 238000009413 insulation Methods 0.000 description 1
- 239000007788 liquid Substances 0.000 description 1
- 238000003754 machining Methods 0.000 description 1
- 238000002844 melting Methods 0.000 description 1
- 230000008018 melting Effects 0.000 description 1
- 229910052757 nitrogen Inorganic materials 0.000 description 1
- 238000002360 preparation method Methods 0.000 description 1
- 238000005476 soldering Methods 0.000 description 1
- 230000007847 structural defect Effects 0.000 description 1
Images
Classifications
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
- B22D15/00—Casting using a mould or core of which a part significant to the process is of high thermal conductivity, e.g. chill casting; Moulds or accessories specially adapted therefor
- B22D15/02—Casting using a mould or core of which a part significant to the process is of high thermal conductivity, e.g. chill casting; Moulds or accessories specially adapted therefor of cylinders, pistons, bearing shells or like thin-walled objects
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
- B22D18/00—Pressure casting; Vacuum casting
- B22D18/04—Low pressure casting, i.e. making use of pressures up to a few bars to fill the mould
-
- 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
- B22D19/0072—Casting in, on, or around objects which form part of the product for making objects with integrated channels
-
- 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
- B22D19/16—Casting in, on, or around objects which form part of the product for making compound objects cast of two or more different metals, e.g. for making rolls for rolling mills
-
- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C38/00—Ferrous alloys, e.g. steel alloys
- C22C38/001—Ferrous alloys, e.g. steel alloys containing N
-
- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C38/00—Ferrous alloys, e.g. steel alloys
- C22C38/02—Ferrous alloys, e.g. steel alloys containing silicon
-
- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C38/00—Ferrous alloys, e.g. steel alloys
- C22C38/04—Ferrous alloys, e.g. steel alloys containing manganese
-
- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C38/00—Ferrous alloys, e.g. steel alloys
- C22C38/06—Ferrous alloys, e.g. steel alloys containing aluminium
-
- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C38/00—Ferrous alloys, e.g. steel alloys
- C22C38/18—Ferrous alloys, e.g. steel alloys containing chromium
- C22C38/40—Ferrous alloys, e.g. steel alloys containing chromium with nickel
- C22C38/42—Ferrous alloys, e.g. steel alloys containing chromium with nickel with copper
-
- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C38/00—Ferrous alloys, e.g. steel alloys
- C22C38/18—Ferrous alloys, e.g. steel alloys containing chromium
- C22C38/40—Ferrous alloys, e.g. steel alloys containing chromium with nickel
- C22C38/58—Ferrous alloys, e.g. steel alloys containing chromium with nickel with more than 1.5% by weight of manganese
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- 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
- F02F3/00—Pistons
- F02F3/16—Pistons having cooling means
- F02F3/20—Pistons having cooling means the means being a fluid flowing through or along piston
-
- 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
- F02F3/00—Pistons
- F02F3/16—Pistons having cooling means
- F02F3/20—Pistons having cooling means the means being a fluid flowing through or along piston
- F02F3/22—Pistons having cooling means the means being a fluid flowing through or along piston the fluid being liquid
-
- 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
- F02F3/00—Pistons
- F02F3/26—Pistons having combustion chamber in piston head
-
- 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
- F02F3/00—Pistons
- F02F3/0015—Multi-part pistons
- F02F3/003—Multi-part pistons the parts being connected by casting, brazing, welding or clamping
- F02F2003/0061—Multi-part pistons the parts being connected by casting, brazing, welding or clamping by welding
-
- 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
- F02F2200/00—Manufacturing
- F02F2200/06—Casting
-
- 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
- F02F3/00—Pistons
- F02F3/10—Pistons having surface coverings
-
- 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
- Y10T29/49249—Piston making
Definitions
- the invention relates to a cast steel piston for internal combustion engines, of a stainless steel alloy having the features of claim 1 or a steel piston partially formed of a stainless steel alloy having the features of claim 11, and a method for producing a one-piece and material einheililtlichen steel piston having the features of claim 14.
- the DE 102 44 513 A1 discloses a method of making a multi-piece cooled piston.
- the piston top is made of heat-resistant steel and the piston base is made of forged AFP steel.
- the subsequent joining or joining of the annular rib of the upper piston part with the support rib of the piston lower part takes place by means of a welding or soldering process.
- the preparation of the parts for joining and the joining process itself represent costly process steps.
- a steel piston for internal combustion engines comprising at least one piston upper part with combustion bowl and an annular wall and a piston base with connecting rod bearing, which is cast from a stainless steel alloy, with the features of claim 1 and by a steel piston only partially from a
- a further inventive solution is given by a method for producing a one-piece and material einheiltlichen steel piston by a low-pressure casting method with the features of claim 14.
- the steel piston is thus cast in one piece and of the same material.
- a substantial simplification of the manufacturing process is achieved.
- the content of Mn and Cr is in the range of Mn 4-6% and Cr is 19-22%.
- Another advantage of this alloy is excellent corrosion resistance at the high temperatures prevailing in the combustion chamber of internal combustion engines. Due to the high strength and good flowability particularly thin or filigree structures of the piston are possible.
- the piston in the piston upper part (12) on one or more cooling channels (4) can be continuous, or divided into several segments. In the latter case can also be spoken by several cooling channels.
- the at least one cooling channel has openings or openings (7, 7 ') to the piston interior and / or to the annular wall (5).
- the openings or openings to the piston interior (7) are used to replace coolant or oil. Typically it acts These are round openings or holes. However, other geometries can be realized as required. This is easy to accomplish, in particular, by the casting method of manufacture selected according to the invention, for example by using suitably shaped casting cores or inserts. In this case, the drilling of openings can be saved.
- the cooling channel (4) can also be interrupted towards the annular wall, so that an opening (7 ') is created. So that the cooling channel (4) with openings to the annular wall (5) does not remain open to the outside, it is closed by at least one closure part (6) to the outside.
- the cooling pipe system is thus constructed in several parts.
- the closure part (6) is preferably formed by a sheet metal or closure plate or a steel ring. For clamping, the closure part can protrude into the cooling channel.
- the closure member is typically welded or soldered. Breakthrough or opening (7 ') and closure part (6) are preferably arranged in the region or within an annular groove (10).
- the at least one cooling channel (4) is formed by a cast-in steel tube (3).
- the steel pipe can still be identified in the cast steel piston due to the irregularities of the structure prevailing in the border area or gate area. If the steel pipe is coated before being poured for better joining, for example with Sn, then a mixed alloy boundary region forms around the cooling channel (4).
- cooling channels (4) are completely through cast-steel tubes (3) formed and the cooling channels (4) have no opening (7 ') to the annular wall out. They are closed to the outside and do not require a closure part (6). Preferably, openings (7) are also present here inwards.
- the cooling pipe system is thus constructed in one piece.
- the steel of the piston and the steel of the cast steel pipe (3) have a different composition.
- an intermediate layer may be formed between the piston and the cast-in steel tube, which has a different composition from the steel of the piston.
- the steel tubes are preferably formed from refractory steels or high-temperature steels. The use of good castable steels is not required.
- the material of the cast-in steel tube can also be the proven steels from the group MoCr4, 42CrMo4, CrMo4 or 31CrMoV6.
- the connecting rod bearing wall (9) has a bearing shell, or the connecting rod bearing wall (9) is at least partially formed by a bearing shell, which consists of a cast-in part.
- the casting, or the bearing shell formed thereby preferably consists of a highly wear-resistant steel.
- a particularly suitable material for a bearing shell can be introduced in a simple manner by casting.
- a material of the bearing shell in particular a steel from the group MoCr4, 42CrMo4, CrMo4 or 31CrMoV6 is selected. If necessary, the bearing shell can also carry special sliding coatings.
- a piston for internal combustion engines which comprises at least one piston upper part (12) with combustion bowl (11) and annular wall (5) and a piston lower part (13) with connecting rod bearing (8).
- the piston lower part (13) is made of a stainless steel alloy having the composition Mn: 4-6, Si: 0.3-1, C: 0.01-0.03, Cr: 19-22, Ni: 1-3, Cu: 0.2-1, N: 0.05-0.17, balance Fe and unavoidable Stahlbegleitmaschineitmaschineitmaschineitmaschineitmaschineitmaschineitmaschinence integrally molded and of the same material and is connected to the piston upper part (12) made of steel by welding.
- the piston upper part can be manufactured in a conventional manner.
- the piston upper part (13) is a forged part.
- the material of the upper piston part is not limited to the steels of the lower part. Rather, the already proven steels can be used. Suitable steels include MoCr4, 42CrMo4, CrMo4 or 31CrMoV6.
- upper piston part (12) and lower piston part (13) takes place according to the invention by welding. Friction welding is particularly preferred.
- the dividing line between upper and lower part can run at different heights of the piston.
- the dividing line is approximately at the lower end of the annular wall (5) (see Fig. 3 ) arranged.
- Another aspect of the invention relates to a particularly suitable method for the production of a casting by casting a steel piston.
- the inventive method for producing a one-piece and material einheililtlichen steel piston which comprises at least one piston upper part (12) with combustion recess (11) and annular wall (5) and a piston lower part (13) with connecting rod bearing (8), provides that a low-pressure casting process is used.
- the molten steel is controlled by means of a riser controlled from below into the mold cavity of the attached mold, with an overpressure of 0.3 to 5 bar, wherein the sprue of the piston takes place from below over the region of the piston recess (11).
- Fig. 1 schematically shows the inflow (2) of the melt from below into the region of the piston recess (11).
- a casting arrangement is selected in which the molten metal is pressed by means of a riser controlled from below, ie against gravity, into the mold cavity of the attached casting mold.
- a mold a mold or sand molds can be used.
- the pressure used in low-pressure casting is usually relatively low and varies between 0.02 and 0.1 MPa, depending on the necessary height of rise and the density of the cast material.
- the casting pressure according to the invention is at an overpressure of about 0.3 to 5 bar. Precise control of the casting pressure and the pressure curve (pressure build-up, holding phase and Reprint) is required for a uniform and void-free mold filling. Preferably 0.5 to 1.5 bar are used.
- the casting furnace and the mold form a chill casting unit, which are connected by the riser.
- the casting furnace is complete pressure-tight.
- the furnace is used in the preferred only to keep warm and not to melt the metal.
- the molten metal is poured over the pressurization of the holding furnace with controlled casting pressure and controlled casting speed low turbulence from below into the mold.
- an inert gas can also be used. Preference is given to working with nitrogen.
- the resulting piston is fed via the pending casting pressure until the end of its solidification. As a result, a denser structure than in chill casting or gravity casting is achieved.
- a feeder is almost completely dispensed with, since the feed is made through the riser.
- the process is designed in such a way that solidification from above takes place directly above the riser pipe up to a defined point and remains liquid in the riser pipe. This can for example be achieved by the riser is heated or receives a special heat insulation. Furthermore, it is possible alone or in addition to the heated riser to cool the mold at specific locations. This is particularly effective if it is a mold of metal or graphite.
- Another variant provides for the use of sand molds and to take advantage of the increasing mold filling, but to dispense with the feed through the riser. Before the cast piston is completely solidified, the gate of the mold is closed. Then the pressure in the low-pressure casting furnace is lowered and the melt returns from the riser pipe into the furnace. This can shorten the process time.
- the low-pressure casting process also has the advantage that the temperature of the melt can be accurately adjusted. As a result, the casting process, or the exact mold filling is well calculated.
- Another advantage of low pressure casting is that casting defects, such as gas inclusions by turbulent mold filling or cold running due to too slow mold filling, are prevented by a precisely controlled mold filling, in particular precisely controlled filling speed.
- a casting is formed, which is one piece and of uniform material. If the steel piston has further special components, such as, for example, cooling channels, there is the possibility that these are integral with the casting in the finished piston and are of the same material.
- one or more inserts are inserted into the mold to form special components of the piston.
- Inlay parts in contrast to the sand cores that can likewise be used for casting, are parts that remain in the cast piston.
- the inserts are expediently made of steel, since there is good material compatibility with the steel of the piston.
- the inserts particularly preferably at least one cooling channel (4) and / or a connecting rod bearing wall (9) are formed.
- steel tubes (3) or steel shells are inserted into the casting mold.
- the inserts are part of sand core packages.
- the steel pipe can also be a sand-filled pipe.
- a uniform preforming of the tube is possible.
- pouring the sand filling prevents accidental breakage of the melt by partial melting of the tube.
- the steel pipe is then filled with foundry sand, if it has an opening (7 ') to the annular wall (5) or large openings (7) to the piston interior.
- the openings (7) for the interior of the piston can be introduced by casting technology and / or by subsequent machining of the casting.
- the opening (7 ') to the annular wall (5) is advantageously formed during casting, since the large opening allows easy and complete removal of core sand contained in the steel pipe.
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- Engineering & Computer Science (AREA)
- Chemical & Material Sciences (AREA)
- Mechanical Engineering (AREA)
- Materials Engineering (AREA)
- Metallurgy (AREA)
- Organic Chemistry (AREA)
- Combustion & Propulsion (AREA)
- General Engineering & Computer Science (AREA)
- Physics & Mathematics (AREA)
- Fluid Mechanics (AREA)
- Pistons, Piston Rings, And Cylinders (AREA)
Description
Die Erfindung betrifft einen gegossenen Stahlkolben für Verbrennungsmotoren, aus einer Edelstahllegierung mit den Merkmalen des Anspruchs 1 oder einen teilweise aus einer Edelstahllegierung gebildeten Stahlkolben mit den Merkmalen des Anspruchs 11, sowie ein Verfahren zur Herstellung eines einstückigen und materialeinheiltlichen Stahlkolbens mit den Merkmalen des Anspruchs 14.The invention relates to a cast steel piston for internal combustion engines, of a stainless steel alloy having the features of
Aufgrund der zunehmenden Anforderungen möglichst hoher Spitzendrücke in Hubkolben-Verbrennungsmotoren die bei bis zu 250 bar liegen, sind die Leichtbau-Aluminiumkolben zunehmend an ihre Leistungsgrenze gestoßen. Daher werden für den LKWaber auch den PKW-Bereich zunehmend wieder Stahlkolben gefordert. Die hohen Anforderungen an Lebensdauer und Zuverlässigkeit machen dabei insbesondere vollständig aus Stahl gefertigte Kolben erforderlich, welche die derzeit noch häufig eingesetzten Kolben aus Stahl und Aluminium ersetzen sollen.Due to the increasing demands of highest possible peak pressures in reciprocating internal combustion engines which are up to 250 bar, the lightweight aluminum pistons have increasingly reached their performance limits. As a result, the truck sector is increasingly demanding steel pistons for the car sector. The high demands on life and reliability make it especially required completely made of steel pistons, which are to replace the still frequently used pistons made of steel and aluminum.
Gegenüber den Aluminium-Kolben haben die Stahlkolben aber den Nachteil eines höheren Gewichts.
Die Herstellung von vollständig aus Stahl gefertigten Kolben ist aufgrund der schwierigen Verarbeitbarkeit von Stahl für filigrane Bauteile häufig aufwändig und kostspielig.Compared to the aluminum pistons but the steel pistons have the disadvantage of a higher weight.
Producing all-steel pistons is often cumbersome and costly, due to the difficult processability of steel for filigree components.
So ist es beispielsweise üblich, die Herstellung des Kolbens durch Verschweißung zweier Schmiedeteile vorzunehmen. Hierdurch ist auch den Einsatz unterschiedlicher Werkstoffe für Ober- und Unterteil möglich.For example, it is customary to carry out the production of the piston by welding two forged parts. As a result, the use of different materials for upper and lower part is possible.
Die
In der
- C ≤ 0.8%, Si ≤ 3%, Mn ≤ 3%, S ≤ 0.2%, Ni ≤ 3%, Cr ≤ 6%, Cu ≤ 6%, Nb 0.01-3%, Rest Fe mit unvermeidbaren Verunreinigungen
- oder C ≤ 0.1-0.8%, S ≤ 3%, Si ≤ 3%, Mn ≤ 3%, S ≤ 0.2%, Ni ≤ 10%, Cr ≤ 30%, Cu ≤ 6%, Nb ≤ 0.05-8% und Rest Fe mit unvermeidbaren Verunreinigungen. Dabei spielen insbesondere die gute Raumtemperatur Streckgrenze sowie eine hohe Hochtemperatur-Zugfestigkeit und Bruchfestigkeit einer Rolle.
- C ≤ 0.8%, Si ≤ 3%, Mn ≤ 3%, S ≤ 0.2%, Ni ≤ 3%, Cr ≤ 6%, Cu ≤ 6%, Nb 0.01-3%, balance Fe with unavoidable impurities
- or C ≤ 0.1-0.8%, S ≤ 3%, Si ≤ 3%, Mn ≤ 3%, S ≤ 0.2%, Ni ≤ 10%, Cr ≤ 30%, Cu ≤ 6%, Nb ≤ 0.05-8% and Rest Fe with unavoidable impurities. In particular, the good room temperature yield strength and a high high-temperature tensile strength and breaking strength play a role.
Aufgrund der filigranen Bauweise eines Kolbens werden besonders hohe Ansprüche an die Fließfähigkeit des Gießmetalls, sowie an das Gießverfahren gestellt. Das Gießverfahren und die Fließfähigkeit des Metalls sind von entscheidender Bedeutung für die Erzielung eines geeigneten und fehlerfreien Gefüges, welches für die hohen Festigkeitsanforderungen der gegossenen Bauteile unerlässlich ist. Bereits kleinste Gefügefehler und Lunker im Gussteil können in den dünnen Wandungen des Kolbens zu einem katastrophalen Werkstoffversagen führen.Due to the filigree design of a piston particularly high demands are placed on the flowability of the cast metal, as well as the casting process. The casting process and the fluidity of the metal are crucial for achieving a suitable and defect-free structure which is essential for the high strength requirements of the cast components. Already the smallest structural defects and voids in the casting can lead to catastrophic material failure in the thin walls of the piston.
Es ist daher Aufgabe der Erfindung, Kolben aus mechanisch hochbelastbaren und kostengünstig zu formenden Stählen bereit zu stellen. Eine weitere erfindungsgemäße Aufgabe ist es, kostengünstiges und einfaches Verfahren zur Herstellung dieser Stahlkolben aufzuzeigen.It is therefore an object of the invention to provide pistons of mechanically heavy duty and inexpensive to be formed steels. Another object of the invention is to provide a cost effective and simple method for producing these steel pistons.
Die Aufgabe wird erfindungsgemäß gelöst, durch einen Stahlkolben für Verbrennungsmotoren, der zumindest ein Kolbenoberteil mit Verbrennungsmulde und eine Ringwand sowie ein Kolbenunterteil mit Pleuellager umfasst, welcher aus einer Edelstahllegierung gegossen ist, mit den Merkmalen des Anspruchs 1 sowie durch einen Stahlkolben der nur teilweise aus einer Edelstahllegierung gegossen ist, mit den Merkmalen des Anspruchs 11. Eine weitere erfindungsgemäße Lösung ist durch ein Verfahren zur Herstellung eines einstückigen und materialeinheiltlichen Stahlkolbens durch ein Niederdruckgießverfahren mit den Merkmalen Anspruchs 14 gegeben.The object is achieved by a steel piston for internal combustion engines, comprising at least one piston upper part with combustion bowl and an annular wall and a piston base with connecting rod bearing, which is cast from a stainless steel alloy, with the features of
Weitere vorteilhafte Ausgestaltungen sind Gegenstand der Unteransprüche.Further advantageous embodiments are the subject of the dependent claims.
Erfindungsgemäß wird der Stahlkolben somit einstückig und materialeinheitlich gegossen. Hierdurch wird eine wesentliche Vereinfachung des Herstellungsverfahrens erreicht. Für die Erfindung ist es damit von wesentlicher Bedeutung, Stahllegierungen zu verwenden, die gießtechnisch gut verarbeitbar sind, eine hohe Festigkeit, beziehungsweise Streckgrenze bei den hohen Einsatztemperaturen aufzuweisen und eine möglichst geringe Materialdichte zu besitzen.According to the invention, the steel piston is thus cast in one piece and of the same material. As a result, a substantial simplification of the manufacturing process is achieved. For the invention, it is therefore essential to use steel alloys which are easy to process by casting, a high strength, respectively Yield point at the high operating temperatures and to have the lowest possible material density.
Die erfindungsgemäß eingesetzte Stahllegierung ist eine Edelstahllegierung sehr guter Fließfähigkeit mit der folgenden Zusammensetzung in Gew.%:
- Mn: 3-9
- Si: 0,3-1
- C: 0,01-0,03
- Cr: 15-27
- Ni: 1-3
- Cu: 0,2-1
- N: 0,05-0,17
- Rest Fe sowie unvermeidliche Stahlbegleitelemente.
- Mn: 3-9
- Si: 0.3-1
- C: 0.01-0.03
- Cr: 15-27
- Ni: 1-3
- Cu: 0.2-1
- N: 0.05-0.17
- Remaining Fe and unavoidable steel accompanying elements.
Bevorzugt liegt der Anteil von Mn und Cr im Bereich von Mn 4-6% und Cr 19-22%.Preferably, the content of Mn and Cr is in the range of Mn 4-6% and Cr is 19-22%.
Ein weiterer Vorteil dieser Legierung ist eine hervorragende Korrosionsbeständigkeit bei den hohen im Brennraum von Verbrennungsmotoren herrschenden Temperaturen. Aufgrund der hohen Festigkeit und guten Fließfähigkeit sind besonders dünne beziehungsweise filigrane Strukturen des Kolbens möglich.Another advantage of this alloy is excellent corrosion resistance at the high temperatures prevailing in the combustion chamber of internal combustion engines. Due to the high strength and good flowability particularly thin or filigree structures of the piston are possible.
Es ist vorgesehen, den Stahlkolben einstückig und materialeinheitlich zu gießen. Darunter ist zu verstehen, dass Kolbenoberteil mit Verbrennungsmulde und Ringwand sowie ein Kolbenunterteil mit Pleuellager aus einem Guss hervorgehen und aus dem gleichen Material bestehen. Hierunter sind aber auch Stahlkolben zu verstehen die weitere An- oder Einbauteile enthalten, die sich hinsichtlich des Materials vom gegossenen Kolben unterscheiden können, oder die nicht während des Gussvorgangs des Kolbens gebildet werden. Unter diesen weiteren Teilen sind beispielsweise Einlegeteile zu verstehen, die an- oder eingegossen werden. Je nach Material und Qualität des Ein- oder Angusses können die An- oder Einlegeteile vom Stahlkolben nicht mehr unterschieden werden, so dass auch Stahlkolben und An- oder Einlegeteile als einstückig und materialeinheitlich gegossen erscheinen.It is intended to pour the steel piston in one piece and of the same material. This is understood to mean that upper piston part with combustion bowl and annular wall and a lower piston part with connecting rod bearing originate from a single casting and consist of the same material. However, this also means steel pistons that contain other attachments or built-in parts that may or may not differ with regard to the material from the cast piston be formed during the casting process of the piston. Among these other parts are, for example, to understand inserts that are poured or poured. Depending on the material and quality of the inlet or sprue, the attachment or insertion parts of the steel piston can no longer be distinguished, so that steel pistons and inserts or inserts appear to be cast in one piece and of the same material.
Zur Erläuterung der Erfindung werden schematische Zeichnungen herangezogen.To illustrate the invention, schematic drawings are used.
Dabei zeigen:
- Fig. 1
- einen Kolben (1) im Querschnitt, mit Schmelzezufluss (2), eingegossenem Stahlrohr (3), Kühlkanal (4), Ringwand (5), Öffnungen des Kühlkanals zur Ringwand (7') und Ringnuten (10),
- Fig. 2
- einen Kolben (1) im Querschnitt, mit Oberteil (12) und Unterteil (13), Ringwand (5), Kühlkanal (4), Öffnung des Kühlkanals (7), Pleuellager (8), Pleuellagerwand (9) und Verbrennungsmulde (11)
- Fig. 3
- einen Kolben (1) im Schnitt, mit Oberteil (12) und Unterteil (13), Ringwand (5), Kühlkanal (4), Verschlussteil (6), Pleuellager (8), Pleuellagerwand (9) und Verbrennungsmulde (11)
- Fig. 1
- a piston (1) in cross-section, with melt inflow (2), cast-steel tube (3), cooling channel (4), annular wall (5), openings of the cooling channel to the annular wall (7 ') and annular grooves (10),
- Fig. 2
- a piston (1) in cross-section, with upper part (12) and lower part (13), annular wall (5), cooling channel (4), opening of the cooling channel (7), connecting rod bearing (8), connecting rod bearing wall (9) and combustion recess (11)
- Fig. 3
- a piston (1) in section, with upper part (12) and lower part (13), annular wall (5), cooling channel (4), closure part (6), connecting rod bearing (8), connecting rod bearing wall (9) and combustion recess (11)
In einer bevorzugten Ausführung weist der Kolben im Kolbenoberteil (12) einen oder mehrere Kühlkanäle (4) auf. Der Kühlkanal kann dabei durchgängig, oder in mehrere Segmente aufgeteilt sein. Im Letzteren Fall kann auch von mehreren Kühlkanälen gesprochen werden. Der zumindest eine Kühlkanal weist Durchbrüche oder Öffnungen (7, 7') zum Kolbeninneren und/oder zur Ringwand (5) aufweisen.In a preferred embodiment, the piston in the piston upper part (12) on one or more cooling channels (4). The cooling channel can be continuous, or divided into several segments. In the latter case can also be spoken by several cooling channels. The at least one cooling channel has openings or openings (7, 7 ') to the piston interior and / or to the annular wall (5).
Die Durchbrüche oder Öffnungen zum Kolbeninneren (7) dienen zum Austausch von Kühlmittel bzw. Öl. Typischerweise handelt es sich hierbei um runde Öffnungen oder um Bohrungen. Es können aber je nach Erfordernis auch andere Geometrien realisiert werden. Dies ist insbesondere durch das erfindungsgemäß gewählte Herstellungsverfahren des Gießens einfach zu bewerkstelligen, beispielsweise indem geeignet geformte Gießkerne oder Einlegeteile verwendet werden. In diesem Fall kann das Bohren von Öffnungen eingespart werden.The openings or openings to the piston interior (7) are used to replace coolant or oil. Typically it acts These are round openings or holes. However, other geometries can be realized as required. This is easy to accomplish, in particular, by the casting method of manufacture selected according to the invention, for example by using suitably shaped casting cores or inserts. In this case, the drilling of openings can be saved.
Des Weiteren kann der Kühlkanal (4) auch zur Ringwand hin unterbrochen sein, so dass eine Öffnung (7') entsteht. Damit der Kühlkanal (4) mit Öffnungen zur Ringwand (5) nicht nach außen geöffnet bleibt, ist er durch mindestens ein Verschlussteil (6) nach außen abgeschlossen. Das Kühlrohrsystem ist somit mehrteilig aufgebaut. Das Verschlussteil (6) ist bevorzugt durch einen Blech oder Verschlussblech oder einen Stahlring gebildet. Zur Verklammerung kann das Verschlussteil dabei in den Kühlkanal hineinragen. Das Verschlussteil ist typischerweise angeschweißt oder angelötet. Durchbruch bzw. Öffnung (7') und Verschlussteil (6) sind bevorzugt im Bereich oder innerhalb einer Ringnut (10) angeordnet.Furthermore, the cooling channel (4) can also be interrupted towards the annular wall, so that an opening (7 ') is created. So that the cooling channel (4) with openings to the annular wall (5) does not remain open to the outside, it is closed by at least one closure part (6) to the outside. The cooling pipe system is thus constructed in several parts. The closure part (6) is preferably formed by a sheet metal or closure plate or a steel ring. For clamping, the closure part can protrude into the cooling channel. The closure member is typically welded or soldered. Breakthrough or opening (7 ') and closure part (6) are preferably arranged in the region or within an annular groove (10).
In einer weiteren bevorzugten Ausgestaltung der Erfindung ist der mindestens eine Kühlkanal (4) durch ein eingegossenes Stahlrohr (3) ausgebildet. In der Regel ist das Stahlrohr auch im gegossenen Stahlkolben aufgrund der im Grenzbereich bzw. Angussbereich herrschenden Unregelmäßigkeiten des Gefüges noch identifizierbar. Ist das Stahlrohr vor dem Eingießen zum Besseren Verbinden beschichtet, beispielsweise mit Sn, so bildet sich ein Grenzbereich aus Mischlegierung um den Kühlkanal (4) herum aus.In a further preferred embodiment of the invention, the at least one cooling channel (4) is formed by a cast-in steel tube (3). As a rule, the steel pipe can still be identified in the cast steel piston due to the irregularities of the structure prevailing in the border area or gate area. If the steel pipe is coated before being poured for better joining, for example with Sn, then a mixed alloy boundary region forms around the cooling channel (4).
In einer weiteren erfindungsgemäßen Variante ist der, beziehungsweise sind die Kühlkanäle (4) vollständig durch eingegossene Stahlrohre (3) gebildet und die Kühlkanäle (4) weisen keine Öffnung (7') zur Ringwand hin auf. Sie sind nach außen geschlossen und erfordern kein Verschlussteil (6). Bevorzugt sind auch hier Öffnungen (7) nach innen vorhanden. Das Kühlrohrsystem ist somit einteilig aufgebaut.In a further variant according to the invention, or the cooling channels (4) are completely through cast-steel tubes (3) formed and the cooling channels (4) have no opening (7 ') to the annular wall out. They are closed to the outside and do not require a closure part (6). Preferably, openings (7) are also present here inwards. The cooling pipe system is thus constructed in one piece.
Es ist möglich, dass der Stahl des Kolbens und der Stahl des eingegossenen Stahlrohrs (3) eine unterschiedliche Zusammensetzung aufweisen. Ebenso kann zwischen Kolben und eingegossenem Stahlrohr eine Zwischenschicht gebildet sein, die eine vom Stahl des Kolbens unterschiedliche Zusammensetzung aufweist. Bevorzugt werden die Stahlrohre aus hochschmelzenden Stählen oder hochwarmfesten Stählen gebildet. Die Verwendung der gut gießfähigen Stähle ist nicht erforderlich.
Bei dem Material des eingegossenen Stahlrohrs kann es sich auch um die bewährten Stähle aus der Gruppe MoCr4, 42CrMo4, CrMo4 oder 31CrMoV6 handeln.It is possible that the steel of the piston and the steel of the cast steel pipe (3) have a different composition. Likewise, an intermediate layer may be formed between the piston and the cast-in steel tube, which has a different composition from the steel of the piston. The steel tubes are preferably formed from refractory steels or high-temperature steels. The use of good castable steels is not required.
The material of the cast-in steel tube can also be the proven steels from the group MoCr4, 42CrMo4, CrMo4 or 31CrMoV6.
In einer weiteren Ausgestaltung der Erfindung weist die Pleuellagerwand (9) eine Lagerschale auf, beziehungsweise ist die Pleuellagerwand (9) zumindest teilweise durch eine Lagerschale gebildet, die aus einem Eingussteil besteht. Das Eingussteil, beziehungsweise die hierdurch gebildete Lagerschale besteht bevorzugt aus einem hochverschleißfesten Stahl. Durch das erfindungsgemäß gewählte Gießen des Stahlkolbens kann in einfacher Weise durch Anguss ein besonders geeignetes Material für eine Lagerschale eingebracht werden. Als Material der Lagerschale wird insbesondere ein Stahl aus der Gruppe MoCr4, 42CrMo4, CrMo4 oder 31CrMoV6 gewählt. Die Lagerschale kann gegebenenfalls auch spezielle Gleitbeschichtungen tragen.In a further embodiment of the invention, the connecting rod bearing wall (9) has a bearing shell, or the connecting rod bearing wall (9) is at least partially formed by a bearing shell, which consists of a cast-in part. The casting, or the bearing shell formed thereby preferably consists of a highly wear-resistant steel. By casting the steel piston selected according to the invention, a particularly suitable material for a bearing shell can be introduced in a simple manner by casting. As a material of the bearing shell in particular a steel from the group MoCr4, 42CrMo4, CrMo4 or 31CrMoV6 is selected. If necessary, the bearing shell can also carry special sliding coatings.
In einer weiteren Variante der Erfindung wird nicht der gesamte Kolben einstückig und Material einheitlich gegossen, sondern nur das Kolbenoberteil. Erfindungsgemäß ist ein Kolben für Verbrennungsmotoren vorgesehen, der zumindest ein Kolbenoberteil (12) mit Verbrennungsmulde (11) und Ringwand (5) sowie ein Kolbenunterteil (13) mit Pleuellager (8) umfasst. Das Kolbenunterteil (13) ist dabei aus einer Edelstahllegierung der Zusammensetzung Mn: 4-6, Si: 0,3-1, C: 0,01-0,03, Cr: 19-22, Ni: 1-3, Cu: 0,2-1, N: 0,05-0,17, Rest Fe sowie unvermeidliche Stahlbegleitelemente einstückig und materialeinheitlich gegossen und mit dem Kolbenoberteil (12) aus Stahl durch Schweißen verbunden ist.In a further variant of the invention, not the entire piston is integrally molded and material uniformly, but only the upper piston part. According to the invention, a piston for internal combustion engines is provided which comprises at least one piston upper part (12) with combustion bowl (11) and annular wall (5) and a piston lower part (13) with connecting rod bearing (8). The piston lower part (13) is made of a stainless steel alloy having the composition Mn: 4-6, Si: 0.3-1, C: 0.01-0.03, Cr: 19-22, Ni: 1-3, Cu: 0.2-1, N: 0.05-0.17, balance Fe and unavoidable Stahlbegleitelemente integrally molded and of the same material and is connected to the piston upper part (12) made of steel by welding.
Hierbei kann das Kolbenoberteil auf konventionelle Weise gefertigt sein. Bevorzugt ist das Kolbenoberteil (13) ein Schmiedeteil.Here, the piston upper part can be manufactured in a conventional manner. Preferably, the piston upper part (13) is a forged part.
Das Material des Kolbenoberteils ist nicht auf die Stähle des Unterteils beschränkt. Vielmehr kann auf die bereits bewährte Stähle zurückgegriffen werden. Zu den geeigneten Stählen zählen unter anderem MoCr4, 42CrMo4, CrMo4 oder 31CrMoV6.The material of the upper piston part is not limited to the steels of the lower part. Rather, the already proven steels can be used. Suitable steels include MoCr4, 42CrMo4, CrMo4 or 31CrMoV6.
Das Fügen von Kolbenoberteil (12) und Kolbenunterteil (13) erfolgt erfindungsgemäß durch Schweißen. Besonders bevorzugt ist das Reibschweißen. Die Trennlinie zwischen Ober- und Unterteil kann je nach Ausgestaltung des Kolbens in unterschiedlicher Höhe des Kolbens verlaufen. Bevorzugt ist die Trennlinie in etwa am unteren Ende der Ringwand (5) (vergleiche
Ein weiterer Aspekt der Erfindung betrifft ein besonders geeignetes Verfahren zur gießtechnischen Herstellung eines Stahlkolbens.Another aspect of the invention relates to a particularly suitable method for the production of a casting by casting a steel piston.
Das erfindungsgemäße Verfahren zur Herstellung eines einstückigenund materialeinheiltlichen Stahlkolbens der zumindest ein Kolbenoberteil (12) mit Verbrennungsmulde (11) und Ringwand (5) sowie ein Kolbenunterteil (13) mit Pleuellager (8) umfasst,
sieht vor, dass ein Niederdruckgießverfahren angewendet wird. Dabei wird die Stahlschmelze mittels eines Steigrohrs kontrolliert von unten her in den Formhohlraum der aufgesetzten Gießform, mit einem Überdruck von 0,3 bis 5 bar gedrückt wird, wobei der Anguss des Kolbens von unten über den Bereich der Kolbenmulde (11) erfolgt.
provides that a low-pressure casting process is used. The molten steel is controlled by means of a riser controlled from below into the mold cavity of the attached mold, with an overpressure of 0.3 to 5 bar, wherein the sprue of the piston takes place from below over the region of the piston recess (11).
Von wesentlicher Bedeutung ist dabei die erfindungsgemäße Anwendung des Nierdruckgussverfahrens auf Stahlschmelzen.Of essential importance is the inventive application of the Nierdruckgussverfahrens on steel melts.
Bei dem Niederdruckgießverfahren wird eine Gießanordnung, gewählt bei der die Metallschmelze mittels eines Steigrohrs kontrolliert von unten her, also entgegen der Schwerkraft, in den Formhohlraum der aufgesetzten Gießform eingedrückt wird. Als Gießform kann eine Kokille oder auch Sandformen verwendet werden. Der komplexen Form des abzugießenden Kolbens gemäß ist es zweckmäßig die Kokille mit Sandkernen zu kombinieren, beziehungsweise Sandkerne oder Kernpakete in die Gießform einzulegen.In the case of the low-pressure casting method, a casting arrangement is selected in which the molten metal is pressed by means of a riser controlled from below, ie against gravity, into the mold cavity of the attached casting mold. As a mold, a mold or sand molds can be used. According to the complex shape of the piston to be cast off, it is expedient to combine the mold with sand cores, or insert sand cores or core packages into the casting mold.
Der beim Niederdruckgießen angewandte Druck ist üblicherweise relativ niedrig und bewegt sich je nach notwendiger Steighöhe und der Dichte des Gusswerkstoffes zwischen 0,02 und 0,1 MPa.The pressure used in low-pressure casting is usually relatively low and varies between 0.02 and 0.1 MPa, depending on the necessary height of rise and the density of the cast material.
Der Gießdruck liegt erfindungsgemäß bei einem Überdruck von ca. 0,3 bis 5 bar. Eine präzise Regelung des Gießdrucks, sowie des Druckverlaufs (Druckaufbau, Haltephase und Nachdruck) ist für eine gleichmäßige und lunkerfreie Formfüllung erforderlich. Bevorzugt werden 0,5 bis 1,5 bar angewendet.The casting pressure according to the invention is at an overpressure of about 0.3 to 5 bar. Precise control of the casting pressure and the pressure curve (pressure build-up, holding phase and Reprint) is required for a uniform and void-free mold filling. Preferably 0.5 to 1.5 bar are used.
Der Gießofen und die Kokille bilden eine Kokillenguss-Einheit, welche durch das Steigrohr verbunden sind. Der Gießofen ist insgesamt druckdicht abgeschlossen. Der Ofen dient in der bevorzugt nur zum Warmhalten und nicht zum Erschmelzen des Metalls. Dabei wird die Metallschmelze über die Druckbeaufschlagung des Warmhalteofens mit geregeltem Gießdruck und gesteuerter Gießgeschwindigkeit turbulenzarm von unten in die Gießform eingegossen. Anstelle von Druckluft kann auch ein inertes Gas verwendet werden. Bevorzugt wird mit Stickstoff gearbeitet. Der entstehende Kolben wird über den anstehenden Gießdruck bis zum Ende seiner Erstarrung nachgespeist. Hierdurch wird ein dichteres Gefüge als beim Kokillenguss oder Schwerkraftguss erreicht wird.The casting furnace and the mold form a chill casting unit, which are connected by the riser. The casting furnace is complete pressure-tight. The furnace is used in the preferred only to keep warm and not to melt the metal. The molten metal is poured over the pressurization of the holding furnace with controlled casting pressure and controlled casting speed low turbulence from below into the mold. Instead of compressed air, an inert gas can also be used. Preference is given to working with nitrogen. The resulting piston is fed via the pending casting pressure until the end of its solidification. As a result, a denser structure than in chill casting or gravity casting is achieved.
Aufgrund der filigranen Form des Kolbens, insbesondere der dünnen Wände, ist ein möglichst lunkerfreier Guss von entscheidender Bedeutung.Due to the filigree shape of the piston, in particular the thin walls, casting as smooth as possible is of crucial importance.
In einer ersten Ausgestaltung wird auf einen Speiser fast vollständig verzichtet, da die Speisung durch das Steigrohr erfolgt. Um diesen Vorteil nutzen zu können, wird in der das Verfahren so ausgelegt, dass die Erstarrung von oben her bis zu einer definierten Stelle direkt über dem Steigrohr erfolgt und im Steigrohr flüssig bleibt. Das kann beispielsweise erreicht werden, indem das Steigrohr beheizt wird oder eine besondere Wärmeisolierung erhält. Des Weiteren ist es möglich alleine oder zusätzlich zum beheizten Steigrohr die Form an speziellen Stellen zu kühlen. Dies ist besonders effektiv, wenn es sich um eine Kokille aus Metall oder Graphit handelt. Eine weitere Variante sieht die Verwendung von Sandformen vor und die Vorteile der steigenden Formfüllung zu nutzen, aber auf die Speisung durch das Steigrohr zu verzichten. Bevor der gegossene Kolben vollständig erstarrt ist, wird der Anschnitt der Form verschlossen. Hierauf wird der Druck im Niederdruckgussofen gesenkt und die Schmelze läuft aus dem Steigrohr in den Ofen zurück. Hierdurch lässt sich die Prozesszeit verkürzen.In a first embodiment, a feeder is almost completely dispensed with, since the feed is made through the riser. In order to be able to use this advantage, the process is designed in such a way that solidification from above takes place directly above the riser pipe up to a defined point and remains liquid in the riser pipe. This can for example be achieved by the riser is heated or receives a special heat insulation. Furthermore, it is possible alone or in addition to the heated riser to cool the mold at specific locations. This is particularly effective if it is a mold of metal or graphite. Another variant provides for the use of sand molds and to take advantage of the increasing mold filling, but to dispense with the feed through the riser. Before the cast piston is completely solidified, the gate of the mold is closed. Then the pressure in the low-pressure casting furnace is lowered and the melt returns from the riser pipe into the furnace. This can shorten the process time.
Gegenüber den konventionellen Gießverfahren hat das Niederdruckgussverfahren auch den Vorteil, dass die Temperatur der Schmelze kann genau eingestellt werden kann. Hierdurch ist der Gießverlauf, beziehungsweise die exakte Formfüllung gut berechenbar.Compared to the conventional casting process, the low-pressure casting process also has the advantage that the temperature of the melt can be accurately adjusted. As a result, the casting process, or the exact mold filling is well calculated.
Ein weiterer Vorteil des Niederdruckgusses ist es, dass Gießfehler, wie Gaseinschlüsse durch turbulente Formfüllung oder Kaltlauf durch zu langsame Formfüllung, durch eine genau gesteuerte Formfüllung, insbesondere genau gesteuerte Füllgeschwindigkeit verhindert werden.Another advantage of low pressure casting is that casting defects, such as gas inclusions by turbulent mold filling or cold running due to too slow mold filling, are prevented by a precisely controlled mold filling, in particular precisely controlled filling speed.
Beim erfindungsgemäßen Verfahren wird ein Gussteil gebildet, das einstückig und materialeinheitlich ist. Weist der Stahlkolben weitere spezielle Bauteile auf, wie beispielsweise Kühlkanäle, besteht die Möglichkeit, dass diese im fertigen Kolben einstückig und materialeinheitlich mit dem Gussstück sind.In the method according to the invention, a casting is formed, which is one piece and of uniform material. If the steel piston has further special components, such as, for example, cooling channels, there is the possibility that these are integral with the casting in the finished piston and are of the same material.
Besonders bevorzugt wird die hinsichtlich Materialeigenschaften und Gießfähigkeit besonders geeignete Edelstahllegierung mit der folgenden Zusammensetzung eingesetzt:
- Mn: 4-6
- Si: 0,3-1
- C: 0,01-0,03
- Cr: 19-22
- Ni: 1-3
- Cu: 0,2-1
- N: 0,05-0,17
- Rest Fe sowie unvermeidliche Stahlbegleitelemente.
- Mn: 4-6
- Si: 0.3-1
- C: 0.01-0.03
- Cr: 19-22
- Ni: 1-3
- Cu: 0.2-1
- N: 0.05-0.17
- Remaining Fe and unavoidable steel accompanying elements.
In bevorzugter Ausgestaltung der Erfindung werden in die Gießform eines oder mehrere Einlegeteile zur Bildung spezieller Bauteile des Kolbens eingelegt. Unter Einlegeteilen sind dabei im Gegensatz zu den ebenso beim Guss verwendbaren Sandkernen Teile zu verstehen, die im gegossenen Kolben verbleiben.In a preferred embodiment of the invention, one or more inserts are inserted into the mold to form special components of the piston. Inlay parts, in contrast to the sand cores that can likewise be used for casting, are parts that remain in the cast piston.
Die Einlegeteile sind dabei zweckmäßigerweise aus Stahl, da hier gute Materialkompatibilität zum Stahl des Kolbens besteht. Mit den Einlegeteilen werden besonders bevorzugt mindestens ein Kühlkanal (4) und/oder eine Pleuellagerwand (9) gebildet. Hierzu werden entsprechend Stahlrohre (3) oder Stahlschalen in die Gießform eingelegt. Bevorzugt sind die Einlegeteile Bestandteil von Sand-Kernpaketen.The inserts are expediently made of steel, since there is good material compatibility with the steel of the piston. With the inserts particularly preferably at least one cooling channel (4) and / or a connecting rod bearing wall (9) are formed. For this purpose steel tubes (3) or steel shells are inserted into the casting mold. Preferably, the inserts are part of sand core packages.
Beim Stahlrohr kann sich auch um ein sandgefülltes Rohr handeln. Durch die Sandfüllung des Rohrs ist ein gleichmäßiges Vorformen des Rohrs möglich. Beim Gießen verhindert die Sandfüllung ein unbeabsichtigtes Durchbrechen der Schmelze durch partielles Aufschmelzen des Rohrs.The steel pipe can also be a sand-filled pipe. By the sand filling of the tube, a uniform preforming of the tube is possible. When pouring the sand filling prevents accidental breakage of the melt by partial melting of the tube.
Besonders bevorzugt ist das Stahlrohr dann mit Formsand gefüllt, wenn es eine Öffnung (7') zur Ringwand (5) oder große Öffnungen (7) zum Kolbeninneren aufweist.Particularly preferably, the steel pipe is then filled with foundry sand, if it has an opening (7 ') to the annular wall (5) or large openings (7) to the piston interior.
Die Öffnungen (7) zum Kolbeninneren können gießtechnisch und/oder durch spätere Bearbeitung des Gussteils eingebracht werden. Dagegen wird die Öffnung (7') zur Ringwand (5) zweckmäßigerweise beim Guss gebildet, da die große Öffnung ein leichtes und vollständiges Entfernen von im Stahlrohr enthaltenen Kernsand ermöglicht.The openings (7) for the interior of the piston can be introduced by casting technology and / or by subsequent machining of the casting. In contrast, the opening (7 ') to the annular wall (5) is advantageously formed during casting, since the large opening allows easy and complete removal of core sand contained in the steel pipe.
Claims (18)
- Steel piston for internal combustion engines, comprising at least a piston crown (12) with a combustion recess (11) and an annular wall (5) and a piston skirt (13) with a small end bearing (8),
characterised in that
the steel piston is cast in one piece and with material uniformity from a stainless steel alloy with the following composition in % by weight:Mn: 3-9 Si: 0.3-1 C: 0.01-0.03 Cr: 15-27 Ni: 1-3 Cu: 0.2-1 N: 0.05-0.17 - Steel piston according to claim 1,
characterised in that
the piston has one or more cooling passages (4) in the piston crown (12) which have at least in part through-holes or openings (7, 7') towards the interior of the piston and/or towards the annular wall (5). - Steel piston according to claim 2,
characterised in that
the at least one cooling passage (4) is represented by a cast-in steel pipe (3). - Steel piston according to claim 2,
characterised in that
the steel of the piston and the steel of the cast-in steel pipe (3) differ in their composition and/or in that an intermediate layer is formed between the piston and the cast-in steel pipe, which has a composition which differs from the steel of the piston. - Steel piston according to any of the preceding claims,
characterised in that
the cooling passages (4) with openings towards the annular wall (5) are blocked against the outside by at least one closing part (6). - Steel piston according to claim 6,
characterised in that
the closing part (6) is represented by sheet metal or ring steel. - Steel piston according to any of claims 1 to 4,
characterised in that
the cooling passages (4) have no opening (7') towards the annular wall and are completely represented by cast-in steel pipes (3). - Steel piston according to any of the preceding claims,
characterised in that
the small end bearing wall (9) comprises a bearing shell which is represented by a cast-in part. - Steel piston according to claim 8,
characterised in that
the cast-in part of the bearing shell is made of a highly wear-resistant steel. - Steel piston according to any of the preceding claims,
characterised in that
the cast-in part of the bearing shell or the cast-in steel pipe (3) is made of a steel of the group including MoCr4, 42CrMo4, CrMo4 or 31CrMoV6. - Steel piston for internal combustion engines, comprising at least a piston crown (12) with a combustion recess (11) and an annular wall (5) and a piston skirt (13) with a small end bearing (8),
characterised in that
the piston skirt (13) is cast in one piece and with material uniformity from a stainless steel alloy with the following composition in % by weight:Mn: 4-6 Si: 0.3-1 C: 0.01-0.03 Cr: 19-22 Ni: 1-3 Cu: 0.2-1 N: 0.05-0.17 - Steel piston according to claim 11,
characterised in that
the piston crown (13) is a forged part. - Steel piston according to claims 11 or 12,
characterised in that
the piston crown (13) is joined to the piston skirt (13) by friction welding. - Method for producing a one-piece and materially uniform steel piston comprising at least a piston crown (12) with a combustion recess (11) and an annular wall (5) and a piston skirt (13) with a small end bearing (8),
characterised in that
a low-pressure casting process is used in which a steel melt is pressed by means of an ascending pipe in a controlled manner from below into the cavity of the casting mould at a positive pressure of 0.3 to 5 bar, wherein the piston is cast on from below over the region of the piston recess (11),
wherein the steel is chosen from a stainless steel alloy with the following composition in % by weight:Mn: 4-6 Si: 0.3-1 C: 0.01-0.03 Cr: 19-22 Ni: 1-3 Cu: 0.2-1 N: 0.05-0.17 - Method according to claim 14,
characterised in that
one or more inserts made of steel are installed into the casting mould to form at least one cooling passage and/or the small end bearing wall (9). - Method according to claim 15,
characterised in that
a closed steel pipe (3) or a partially open steel pipe (3) filled with core sand is installed to form a cooling passage (4). - Method according to claim 15 or 16,
characterised in that
at least one casting core or a core package is installed into the casting mould to form cooling passages (4). - Method according to claim 17,
characterised in that
the core package comprises inserts made of steel.
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
DE102006030699.6A DE102006030699B4 (en) | 2006-06-30 | 2006-06-30 | Cast steel piston for internal combustion engines |
EP07725968A EP2035170B1 (en) | 2006-06-30 | 2007-06-12 | Cast steel piston for internal combustion engines |
Related Parent Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
EP07725968.7 Division | 2007-06-12 |
Publications (2)
Publication Number | Publication Date |
---|---|
EP2184120A1 EP2184120A1 (en) | 2010-05-12 |
EP2184120B1 true EP2184120B1 (en) | 2011-01-12 |
Family
ID=38537790
Family Applications (2)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
EP09014391A Ceased EP2184120B1 (en) | 2006-06-30 | 2007-06-12 | Moulded steel piston for combustion engines |
EP07725968A Ceased EP2035170B1 (en) | 2006-06-30 | 2007-06-12 | Cast steel piston for internal combustion engines |
Family Applications After (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
EP07725968A Ceased EP2035170B1 (en) | 2006-06-30 | 2007-06-12 | Cast steel piston for internal combustion engines |
Country Status (5)
Country | Link |
---|---|
US (1) | US8528513B2 (en) |
EP (2) | EP2184120B1 (en) |
JP (2) | JP2009541590A (en) |
DE (3) | DE102006030699B4 (en) |
WO (1) | WO2008000347A2 (en) |
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-
2006
- 2006-06-30 DE DE102006030699.6A patent/DE102006030699B4/en not_active Expired - Fee Related
-
2007
- 2007-06-12 US US12/302,723 patent/US8528513B2/en not_active Expired - Fee Related
- 2007-06-12 DE DE502007005685T patent/DE502007005685D1/en active Active
- 2007-06-12 JP JP2009516931A patent/JP2009541590A/en active Pending
- 2007-06-12 DE DE502007006278T patent/DE502007006278D1/en active Active
- 2007-06-12 EP EP09014391A patent/EP2184120B1/en not_active Ceased
- 2007-06-12 EP EP07725968A patent/EP2035170B1/en not_active Ceased
- 2007-06-12 WO PCT/EP2007/005155 patent/WO2008000347A2/en active Application Filing
-
2012
- 2012-08-16 JP JP2012180654A patent/JP2013014845A/en active Pending
Also Published As
Publication number | Publication date |
---|---|
DE102006030699B4 (en) | 2014-10-02 |
US8528513B2 (en) | 2013-09-10 |
DE102006030699A1 (en) | 2008-01-03 |
EP2035170A2 (en) | 2009-03-18 |
EP2184120A1 (en) | 2010-05-12 |
DE502007005685D1 (en) | 2010-12-30 |
US20090178640A1 (en) | 2009-07-16 |
WO2008000347A3 (en) | 2008-02-21 |
JP2009541590A (en) | 2009-11-26 |
JP2013014845A (en) | 2013-01-24 |
DE502007006278D1 (en) | 2011-02-24 |
WO2008000347A2 (en) | 2008-01-03 |
EP2035170B1 (en) | 2010-11-17 |
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