EP2228462A1 - Method for applying a coating to a valve seat of a workpiece and workpiece with a coated valve seat - Google Patents
Method for applying a coating to a valve seat of a workpiece and workpiece with a coated valve seat Download PDFInfo
- Publication number
- EP2228462A1 EP2228462A1 EP10152429A EP10152429A EP2228462A1 EP 2228462 A1 EP2228462 A1 EP 2228462A1 EP 10152429 A EP10152429 A EP 10152429A EP 10152429 A EP10152429 A EP 10152429A EP 2228462 A1 EP2228462 A1 EP 2228462A1
- Authority
- EP
- European Patent Office
- Prior art keywords
- coating
- seat surface
- bore
- workpiece
- nozzle
- 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.)
- Granted
Links
- 238000000576 coating method Methods 0.000 title claims abstract description 92
- 239000011248 coating agent Substances 0.000 title claims abstract description 89
- 238000000034 method Methods 0.000 title claims abstract description 30
- 239000000463 material Substances 0.000 claims abstract description 42
- 239000000843 powder Substances 0.000 claims abstract description 6
- 230000015572 biosynthetic process Effects 0.000 claims abstract description 5
- 238000010894 electron beam technology Methods 0.000 claims abstract description 3
- 238000002347 injection Methods 0.000 claims description 33
- 239000007924 injection Substances 0.000 claims description 33
- PXHVJJICTQNCMI-UHFFFAOYSA-N Nickel Chemical compound [Ni] PXHVJJICTQNCMI-UHFFFAOYSA-N 0.000 claims description 14
- 239000000956 alloy Substances 0.000 claims description 14
- 238000005260 corrosion Methods 0.000 claims description 14
- 230000007797 corrosion Effects 0.000 claims description 14
- 229910045601 alloy Inorganic materials 0.000 claims description 13
- 239000011651 chromium Substances 0.000 claims description 8
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 claims description 7
- VYZAMTAEIAYCRO-UHFFFAOYSA-N Chromium Chemical compound [Cr] VYZAMTAEIAYCRO-UHFFFAOYSA-N 0.000 claims description 6
- 229910052804 chromium Inorganic materials 0.000 claims description 6
- 229910052759 nickel Inorganic materials 0.000 claims description 6
- 229910000531 Co alloy Inorganic materials 0.000 claims description 4
- 239000010687 lubricating oil Substances 0.000 claims description 4
- 229910052742 iron Inorganic materials 0.000 claims description 3
- 239000000446 fuel Substances 0.000 description 18
- 238000002485 combustion reaction Methods 0.000 description 13
- 239000000126 substance Substances 0.000 description 8
- 230000003628 erosive effect Effects 0.000 description 5
- 238000004519 manufacturing process Methods 0.000 description 5
- IJGRMHOSHXDMSA-UHFFFAOYSA-N Atomic nitrogen Chemical compound N#N IJGRMHOSHXDMSA-UHFFFAOYSA-N 0.000 description 2
- 229910001347 Stellite Inorganic materials 0.000 description 2
- 238000005299 abrasion Methods 0.000 description 2
- AHICWQREWHDHHF-UHFFFAOYSA-N chromium;cobalt;iron;manganese;methane;molybdenum;nickel;silicon;tungsten Chemical compound C.[Si].[Cr].[Mn].[Fe].[Co].[Ni].[Mo].[W] AHICWQREWHDHHF-UHFFFAOYSA-N 0.000 description 2
- 239000000295 fuel oil Substances 0.000 description 2
- 239000011159 matrix material Substances 0.000 description 2
- 229910052751 metal Inorganic materials 0.000 description 2
- 239000002184 metal Substances 0.000 description 2
- 230000002028 premature Effects 0.000 description 2
- 238000003466 welding Methods 0.000 description 2
- DGAQECJNVWCQMB-PUAWFVPOSA-M Ilexoside XXIX Chemical compound C[C@@H]1CC[C@@]2(CC[C@@]3(C(=CC[C@H]4[C@]3(CC[C@@H]5[C@@]4(CC[C@@H](C5(C)C)OS(=O)(=O)[O-])C)C)[C@@H]2[C@]1(C)O)C)C(=O)O[C@H]6[C@@H]([C@H]([C@@H]([C@H](O6)CO)O)O)O.[Na+] DGAQECJNVWCQMB-PUAWFVPOSA-M 0.000 description 1
- 229910000831 Steel Inorganic materials 0.000 description 1
- NINIDFKCEFEMDL-UHFFFAOYSA-N Sulfur Chemical compound [S] NINIDFKCEFEMDL-UHFFFAOYSA-N 0.000 description 1
- 229910017052 cobalt Inorganic materials 0.000 description 1
- 239000010941 cobalt Substances 0.000 description 1
- GUTLYIVDDKVIGB-UHFFFAOYSA-N cobalt atom Chemical compound [Co] GUTLYIVDDKVIGB-UHFFFAOYSA-N 0.000 description 1
- 239000000567 combustion gas Substances 0.000 description 1
- 150000001875 compounds Chemical class 0.000 description 1
- 230000006835 compression Effects 0.000 description 1
- 238000007906 compression Methods 0.000 description 1
- 238000010276 construction Methods 0.000 description 1
- 230000001419 dependent effect Effects 0.000 description 1
- 239000002283 diesel fuel Substances 0.000 description 1
- 239000003344 environmental pollutant Substances 0.000 description 1
- 230000004927 fusion Effects 0.000 description 1
- 239000007789 gas Substances 0.000 description 1
- 230000009931 harmful effect Effects 0.000 description 1
- 238000010438 heat treatment Methods 0.000 description 1
- 238000012423 maintenance Methods 0.000 description 1
- 238000005297 material degradation process Methods 0.000 description 1
- 239000006199 nebulizer Substances 0.000 description 1
- 229910052757 nitrogen Inorganic materials 0.000 description 1
- 239000002245 particle Substances 0.000 description 1
- 231100000719 pollutant Toxicity 0.000 description 1
- 238000010248 power generation Methods 0.000 description 1
- 238000010926 purge Methods 0.000 description 1
- 238000009420 retrofitting Methods 0.000 description 1
- 239000011265 semifinished product Substances 0.000 description 1
- 229910052708 sodium Inorganic materials 0.000 description 1
- 239000011734 sodium Substances 0.000 description 1
- 239000007858 starting material Substances 0.000 description 1
- 239000010959 steel Substances 0.000 description 1
- 229910052717 sulfur Inorganic materials 0.000 description 1
- 239000011593 sulfur Substances 0.000 description 1
- 229910052720 vanadium Inorganic materials 0.000 description 1
- GPPXJZIENCGNKB-UHFFFAOYSA-N vanadium Chemical compound [V]#[V] GPPXJZIENCGNKB-UHFFFAOYSA-N 0.000 description 1
Images
Classifications
-
- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C26/00—Coating not provided for in groups C23C2/00 - C23C24/00
-
- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C24/00—Coating starting from inorganic powder
- C23C24/08—Coating starting from inorganic powder by application of heat or pressure and heat
- C23C24/10—Coating starting from inorganic powder by application of heat or pressure and heat with intermediate formation of a liquid phase in the layer
- C23C24/103—Coating with metallic material, i.e. metals or metal alloys, optionally comprising hard particles, e.g. oxides, carbides or nitrides
-
- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
- C23C4/04—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge characterised by the coating material
- C23C4/06—Metallic material
-
- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
- C23C4/12—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge characterised by the method of spraying
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F02—COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
- F02M—SUPPLYING COMBUSTION ENGINES IN GENERAL WITH COMBUSTIBLE MIXTURES OR CONSTITUENTS THEREOF
- F02M61/00—Fuel-injectors not provided for in groups F02M39/00 - F02M57/00 or F02M67/00
- F02M61/16—Details not provided for in, or of interest apart from, the apparatus of groups F02M61/02 - F02M61/14
- F02M61/166—Selection of particular materials
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F02—COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
- F02M—SUPPLYING COMBUSTION ENGINES IN GENERAL WITH COMBUSTIBLE MIXTURES OR CONSTITUENTS THEREOF
- F02M61/00—Fuel-injectors not provided for in groups F02M39/00 - F02M57/00 or F02M67/00
- F02M61/16—Details not provided for in, or of interest apart from, the apparatus of groups F02M61/02 - F02M61/14
- F02M61/18—Injection nozzles, e.g. having valve seats; Details of valve member seated ends, not otherwise provided for
- F02M61/1886—Details of valve seats not covered by groups F02M61/1866 - F02M61/188
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F02—COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
- F02M—SUPPLYING COMBUSTION ENGINES IN GENERAL WITH COMBUSTIBLE MIXTURES OR CONSTITUENTS THEREOF
- F02M2200/00—Details of fuel-injection apparatus, not otherwise provided for
- F02M2200/90—Selection of particular materials
- F02M2200/9038—Coatings
Definitions
- the invention relates to a method for applying a coating to a seat surface of a workpiece, in particular a seat in a nozzle body of an injection nozzle of a two-stroke large diesel engine, and a workpiece, in particular injection nozzle with a coated seat according to the preamble of the independent claim of the respective category.
- needle valves have a seat surface which is often provided deep in very long thin bores such that a nozzle needle of the valve, for example a nozzle needle in an injection valve for injecting fuel into the combustion chamber of an internal combustion engine, with the seat functionally cooperate.
- the nozzle needle interacts functionally with the seat as a valve.
- fuel can flow from a pressure chamber into a longitudinal bore adjoining the valve seat downstream and from there into the combustion chamber of the internal combustion engine via nozzle holes. If the nozzle needle moves back into the valve seat, so the fuel supply to the nozzle holes is interrupted and the injection of the fuel is terminated in the Berennraum.
- injectors such as injectors, control valves for injection components, such as control valves for injection pumps, seats in lubricating oil holes in cylinder inserts of internal combustion engines, for example, in two-stroke large diesel engines, etc.
- injectors control valves for injection components
- control valves for injection pumps seats in lubricating oil holes in cylinder inserts of internal combustion engines, for example, in two-stroke large diesel engines, etc.
- workpieces that are operated in an aggressive environment made of corrosion-resistant materials, so that the corresponding component is protected, among other things against high temperatures or chemical attack.
- a prominent example of such a highly loaded component are injection nozzles for two-stroke large diesel engines, which are often operated, among other things, with highly aggressive heavy oil.
- a heavy oil or other diesel fuel - is introduced by means of fuel injection nozzles in the combustion chamber.
- injectors normally include a nozzle head partially projecting into the combustion chamber, also referred to as a nebulizer.
- the nozzle head is a wear part, which is subject to a high thermal, mechanical and chemical load collective. Depending on the degree of stress, damage to the nozzle head may occur, for example material removal as a result of corrosion, erosion and / or abrasion, or even cracks that can lead to breakup.
- the mechanical loads are also based on the high injection pressure, which can be over a thousand bar. Inside the nozzle head, material losses due to cavitation and / or erosion can occur.
- the thermal loads are based on the high temperatures in the Combustion chamber and the enormous temperature changes between the combustion temperature and the temperature of the freshly supplied purge air. Also in the interior of the nozzle head, through which the fuel is introduced, the intermittent injection leads to shock-like temperature changes.
- the chemical load of the nozzle head is mainly due to high temperature or hot corrosion. Hot corrosion, which is primarily caused by vanadium, sodium and sulfur contained in the fuel, promotes material degradation and erosion. In particular, the corrosion is the reason that a nozzle head can be unusable after a few thousand hours of operation and must be replaced.
- alloys with high chromium and nickel content in which the chromium and nickel content is, for example, around 50% weight percent, but above all, alloys with a chromium content of more than 50% - weight percent, such as Cr / Ni 65/35 alloys, which are produced by means of a so-called HIP process, although have very good properties in relation to the above-mentioned problems with high-temperature or hot corrosion.
- Such materials with high chromium content and excellent chemical properties in terms of high-temperature and hot corrosion are already in the EP 1 353 061 disclosed and described in detail.
- good corrosion properties of certain materials are at the expense of hardness.
- the nozzle bodies themselves are well protected against chemically and physically aggressive environments.
- the seating surfaces with which, for example, the nozzle needles co-operate are insufficient in hardness, which can cause the respective seating surfaces and / or the nozzle needles to wear prematurely, which can lead to leaks, fuel metering inaccuracies, and the like.
- Fig. 2a will be briefly considered as an example of an injection nozzle for a two-stroke large diesel engine.
- the reference numerals to features of known workpieces are provided with an apostrophe, while the reference numerals to inventive features carry no apostrophe in the context of this application.
- the known injection nozzle 31 'of Fig. 2a includes a nozzle body 300 'having a nozzle head 301' connected to the nozzle body 300 '.
- the connection takes place by means of a holding sleeve 302 ', which tapers at its lower end to the longitudinal axis A' of the fuel injector 31 'out.
- the longitudinal axis A ' is at the same time also the longitudinal axis A' of the nozzle head 301 '.
- the retaining sleeve 302 ' is by means of a union nut 303' and an elastic member 304 ', for example a snap ring, attached to the nozzle body 300'.
- the nozzle head 301 ' is supported in the tapered portion of the retaining sleeve 302' from.
- the nozzle head 301 ' has a longitudinal bore 305' and in the region of its lower end at least one nozzle hole 306 ', typically z. B. five nozzle holes 306 ', from the longitudinal bore 305' go out and through which the fuel in the combustion chamber B 'can escape.
- a pressure chamber 307' is provided, in which a feed line 308 'opens for the fuel.
- the pressure chamber 307 ' is bounded in the axial direction by a valve seat 2'.
- a nozzle needle 7' is arranged, which extends substantially in the direction of the longitudinal axis A 'and which cooperates with the valve seat 2'. In the in Fig. 2a shown closed position, the lower tip of the nozzle needle 7 'is pressed into the valve seat 2', so that the passage from the pressure chamber 307 'in the downstream adjoining longitudinal bore 305' is closed.
- the nozzle needle 7 ' is spring-loaded in a conventional manner by means of a compression spring, not shown, and biased against the valve seat 2'. In the open position of the nozzle needle 7 ', this is lifted up out of the valve seat 2', so that between the lower end of the nozzle needle 7 'and the valve seat 2', a passage is open, through which the fuel from the pressure chamber 307 'in the longitudinal bore 305 'can get.
- the volume between the valve seat 2 'and the nozzle holes 306' is commonly referred to as a blind hole.
- the longitudinal bore 305 ' is designed in the specific example described here as a substantially cylindrical bore which extends in the direction of the longitudinal axis A'.
- the diameter d 'of the longitudinal bore 305' defines a flow area, which means the available for the flow of the fuel cross-sectional area in the longitudinal bore 305 'is meant.
- the nozzle needle 7 ' is in the bore 4', which in Fig. 2a for reasons of space only partially shown, provided and has an inlet opening 5 ', through which the nozzle needle 7' in the bore 4 'can be inserted.
- the seat surface 2 ' is provided from the inlet opening 5' at a distance L ', wherein the bore 4' itself has an inner diameter D ', which is slightly larger than an outer diameter of the nozzle needle 7', so that the nozzle needle 7 'safe and precisely in the bore 4 'is guided.
- the distance L ' is typically large against the diameter D' of the bore 4 '. That is, when in the context of the present application of a long thin bore is mentioned, then it is meant a bore whose diameter is small compared to a typical or typical for the bore length.
- the diameter of the bore is e.g. About 10% of the relevant length of the bore, which of course also significantly different ratios of diameter to bore are possible, depending on which workpiece it is.
- the object of the invention is therefore to propose a method for applying a coating to a seat surface of a workpiece, as well as a corresponding workpiece, so that the known from the prior art problems with the seat surfaces of the workpiece are avoided, and in particular higher service life and thus shorter maintenance intervals and ultimately a higher level of operational reliability is achieved.
- a further object of the invention is to provide a method with which a coating can be produced on a seating surface in a thin and long bore.
- a method is to be made available with which a seat in a thin and long bore of a workpiece can be retrofitted with a coating.
- a method for applying a coating to a seat surface of a workpiece wherein the seat is provided within a bore in the workpiece at a predetermined distance from an inlet opening of the bore.
- a coating material is applied to the seat surface in a preceding process step, and in a further process step the coating is formed on the seat surface by means of an energy beam, by directing the energy beam through the bore onto the seat surface.
- the method of the present invention it is possible for the first time to choose the material properties of a base material from which a workpiece, such as an injection nozzle for a two-stroke large diesel engine is made, completely independent of the material requirements are required to a reliably functioning seat deep inside a long thin bore in the workpiece.
- a Ni-based, Cr-based, Cu-based or Fe-based alloy material which is relatively soft but offers very good protection against hot gas corrosion or chemical attack.
- a coating material for the seat for example, a significantly harder material can be selected, so that the seat against permanent mechanical stress better against premature wear, for example. is protected by material removal, cavitation, erosion, micro-welding or material fatigue, etc.
- the coating of the seat surface is made of a softer material than the workpiece itself, for example, to achieve a better seal on the seat or other or to realize another desired material property on the seat
- a material of a metal matrix with embedded particles whose hardness is equal to or higher than that of the metal matrix are used.
- the coating on the seat can be optimized by the coating on the seat.
- the seat itself must be protected against other corrosive processes, such as e.g. an outer wall of the workpiece itself, which is exposed to another aggressive environment with harmful effects.
- the present invention is so flexible that by suitable choice of the material for the coating on the Seat and / or the fact that the coating process itself certain coating conditions are selected specifically, such as the energy density of the energy beam or the action of the energy beam during the coating process, virtually any desired property of the coating on the seat can be selectively adjusted.
- the coating material is applied to an energy input by the energy beam, preferably in the form of a coating powder and / or in the form of a coating wire, or in the form of small pieces of a coating wire and / or in the form of a prefabricated coating body at least on a part of the seat.
- the coating material may also be applied to the seating surface simultaneously with energy input by the energy beam, i. It is a special case of the well-known order welding.
- a new workpiece e.g. a new injection nozzle for a two-stroke large diesel engine
- a function hole can be introduced through which can be transported in the operating state, for example, fuel.
- a laser beam is used as the energy beam, but also other energy beams such as an electron beam can be used advantageously in certain cases.
- the seat is provided in a workpiece according to the invention in a long thin bore deep in the workpiece, wherein a smallest diameter of the bore in a region between the inlet opening and the seat maximum 50% of the distance, in particular not more than 25% of the distance, and the smallest diameter of the Bore preferably a maximum of 10% of the distance from the inlet opening amounts.
- the workpiece is preferred, but not necessary, a nozzle body of a nozzle, in particular an injection nozzle of a two-stroke large diesel engine, or a safety valve or a control valve for a component of an injection system or a lubricating oil hole in a cylinder insert.
- a coating material is in principle any material in question, with which a desired property of the coating can be adjusted on the seat.
- a cobalt-based alloy, and / or a chromium-based alloy and / or a nickel-based alloy and / or an iron-based alloy may be used as coating material.
- the invention further relates to a workpiece in which a seat surface is provided within a bore at a predetermined distance from an entrance opening of the bore, wherein on the seat surface, a coating is formed, which made by means of a directed through the bore on the seat energy beam from a coating material is.
- a function bore can be provided through the coating.
- a smallest diameter of the bore is in a region between the inlet opening and the seat maximum 50% of the distance, in particular a maximum of 25% of the distance, and the smallest diameter of the bore may preferably not exceed 10% of the distance of the seat from the inlet opening amount.
- a hardness of the coating other than a hardness of the workpiece and / or a corrosion resistance of the coating may be different from a corrosion resistance of the workpiece and / or any other property of the coating differ from the corresponding characteristic of the workpiece.
- a first simple embodiment of a method for producing a coating 1 on a seat surface 2 in a long thin bore 4 of a workpiece 3 is exemplified.
- the workpiece 3 of Fig. 1 is a partially sectional control valve 3 of a component of an injection system for a two-stroke large diesel engine.
- the seat 2 is used in the assembled state of the control valve 3 for supporting a movable along the axis A valve needle, which is used only after application of the coating 1 to the valve seat 2 in the control valve 3.
- the hole 4 according to Fig. 1a - 1c it is a thin long hole in the sense of registration.
- the bore has a diameter of 3.5 mm and the Seat 2 is arranged from the inlet opening 5 at a distance L of about 25 mm deep in the bore. That is, the smallest diameter D of the bore, which is constant in the present case along the axis A, is only about 14% of the distance L of the seat 2 of the input port. 5
- the coating powder 100 is heated, thereby wholly or partially melted or melted, so that finally on the seat 2, the coating 2 is formed, for example due to formation of a fusion metallurgical compound or adherence of the layer.
- Fig. 1 c is to see the finished coating 1 on the seat 2, which may need to be reworked, if necessary, to ensure a secure fit of the valve needle, not shown on the coating 1.
- a per se known injector 31 'for a two-stroke large diesel engine with a coating 1 can be retrofitted.
- Fig. 2a is an injection nozzle 31 'known from the prior art partially and schematically shown in section.
- the Fig. 2a has already been described in detail above, so that with the description of the Fig. 2b is continued.
- a prefabricated coating body 102 made of a coating material 100 was placed on the seat surface 2 through the bore 4. Since the injection nozzle 3, 31 is already a workpiece 3 according to the present invention at the latest, and no longer an injection nozzle 31 'known from the prior art, from now on all reference symbols without apostrophes are used, since the corresponding ones are used Features relate to an inventive injection nozzle 3, 31.
- Fig. 2d is the completion of the seat 1 just completed.
- the laser is about to shut down.
- the coating body 102 was heated by the laser beam 6 from the laser 600 in a predetermined heating process such that the coating body 102 was reliably connected to the seat surface 2 and thus forms a coating 1 according to the present invention on the seat surface 2.
- a known per se injection valve has been successfully retrofitted with a seat coating 1 according to the invention.
- Fig. 3a is a blank of a nozzle head 301 partially and schematically shown in section.
- the blank of the nozzle head 301 has a blind bore 4, at the lower end of which a seat 2 is provided at a distance L from an inlet opening 5 such that the seat surface 2 extends over the entire cross section of the blind hole 4.
- a coating powder 100, 101 introduced, which covers the seat 2.
- the laser 600 has just been switched on and heated with the laser beam 6 through the bore 4 through the coating material 100, 101, whereby a coating 1 on the seat surface 2 is formed.
- Fig. 3b the laser 600 has already been switched off because the coating 1 on the seat surface 2 is finished.
- the injection nozzle 31 can fulfill its function, according to Fig. 3c by means of a suitable drill through the bore 4 through a longitudinal bore 305 in the form of a blind hole through the coating 1 and the seat 2 is introduced.
- the nozzle head according to the invention is therefore suitable, inter alia, in particular for future generations of large diesel engines, which are even more powerful and place even greater demands on the load capacity of the nozzle heads.
- already in-service components according to the invention can be retrofitted.
- the invention is not limited to special applications in large diesel engines, but the invention can be used successfully wherever long thin holes in the sense of present invention seating surfaces must be provided with coatings that have to fulfill certain functions.
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- Chemical & Material Sciences (AREA)
- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Chemical Kinetics & Catalysis (AREA)
- Materials Engineering (AREA)
- Metallurgy (AREA)
- Organic Chemistry (AREA)
- Plasma & Fusion (AREA)
- Physics & Mathematics (AREA)
- Combustion & Propulsion (AREA)
- General Engineering & Computer Science (AREA)
- Fuel-Injection Apparatus (AREA)
- Laser Beam Processing (AREA)
- Other Surface Treatments For Metallic Materials (AREA)
Abstract
Description
Die Erfindung betrifft ein Verfahren zum Aufbringen einer Beschichtung auf eine Sitzfläche eines Werkstücks, insbesondere auf eine Sitzfläche in einem Düsenkörper einer Einspritzdüse eines Zweitakt-Grossdieselmotors, sowie ein Werkstück, insbesondere Einspritzdüse mit einer beschichteten Sitzfläche gemäss dem Oberbegriff des unabhängigen Anspruchs der jeweiligen Kategorie.The invention relates to a method for applying a coating to a seat surface of a workpiece, in particular a seat in a nozzle body of an injection nozzle of a two-stroke large diesel engine, and a workpiece, in particular injection nozzle with a coated seat according to the preamble of the independent claim of the respective category.
Es ist wohl bekannt, dass beispielsweise Nadelventile eine Sitzfläche aufweisen, die oft tief in sehr langen dünnen Bohrungen derart vorgesehen ist, dass eine Düsennadel des Ventils, zum Beispiel eine Düsennadel in einem Einspritzventil zum Einspritzen von Kraftstoff in den Brennraum einer Brennkraftmaschine, mit der Sitzfläche funktional zusammenwirken kann. So wirkt zum Beispiel im Fall von Einspritzdüsen die Düsennadel mit der Sitzfläche funktional als Ventil zusammen. Wenn sich die Düsennadel aus dem Ventilsitz heraus hebt, kann Treibstoff aus einem Druckraum in eine sich stromabwärts an den Ventilsitz anschliessende Längsbohrung strömen und von dort über Düsenlöcher in den Brennraum der Bennkraftmaschine gelangen. Wird die Düsennadel wieder in den Ventilsitz zurück bewegt, so wird die Treibstoffzufuhr zu den Düsenlöchern unterbrochen und die Einspritzung des Treibstoffs in den Berennraum beendet.It is well known that, for example, needle valves have a seat surface which is often provided deep in very long thin bores such that a nozzle needle of the valve, for example a nozzle needle in an injection valve for injecting fuel into the combustion chamber of an internal combustion engine, with the seat functionally cooperate. For example, in the case of injectors, the nozzle needle interacts functionally with the seat as a valve. When the nozzle needle lifts out of the valve seat, fuel can flow from a pressure chamber into a longitudinal bore adjoining the valve seat downstream and from there into the combustion chamber of the internal combustion engine via nozzle holes. If the nozzle needle moves back into the valve seat, so the fuel supply to the nozzle holes is interrupted and the injection of the fuel is terminated in the Berennraum.
Dabei werden an die in Rede stehenden Werkstücke wie Einspritzdüsen, Steuerventile für Einspritzkomponenten, wie zum Beispiel Steuerventile für Einspritzpumpen, Sitzflächen in Schmierölbohrungen in Zylindereinsätzen von Verbrennungsmotoren, zum Beispiel in Zweitakt-Grossdieselmotoren usw. oft spezielle Anforderungen hinsichtlich des verwendbaren Materials gestellt. So werden beispielsweise Werkstücke, die in einer aggressiven Umgebung betrieben werden aus korrosionsfesten Materialien hergestellt, so dass die entsprechende Komponente unter anderem gegen hohe Temperaturen oder chemische Angriffe geschützt ist.Here are the specific work in question such as injectors, control valves for injection components, such as control valves for injection pumps, seats in lubricating oil holes in cylinder inserts of internal combustion engines, for example, in two-stroke large diesel engines, etc. often made special requirements regarding the usable material. For example, workpieces that are operated in an aggressive environment made of corrosion-resistant materials, so that the corresponding component is protected, among other things against high temperatures or chemical attack.
Ein prominentes Beispiel einer solchen hoch belasteten Komponente sind Einspritzdüsen für Zweitakt-Grossdieselmotoren, die unter anderem oft mit hochaggressivem Schweröl betrieben werden.A prominent example of such a highly loaded component are injection nozzles for two-stroke large diesel engines, which are often operated, among other things, with highly aggressive heavy oil.
Bei Grossdieselmotoren, die unter anderem als Antriebsaggregate für Schiffe oder zur Stromerzeugung in Stationäranlagen verwendet werden, wird der Brennstoff - typischerweise ist das, wie oben erwähnt ein Schweröl oder ein anderer Dieselbrennstoff - mittels Brennstoffeinspritzdüsen in den Verbrennungsraum eingebracht. Diese Einspritzdüsen umfassen normalerweise einen teilweise in den Verbrennungsraum hineinragenden Düsenkopf, der auch als Zerstäuber bezeichnet wird. Der Düsenkopf ist ein Verschleissteil, das einem hohen thermischen, mechanischen und chemischen Belastungskollektiv unterliegt. Je nach Grad der Belastung können am Düsenkopf Schäden, beispielsweise Materialabtrag infolge von Korrosion, Erosion und / oder Abrasion auftreten, oder auch Risse, die bis zum Auseinanderbrechen führen können.In large diesel engines, which are used, inter alia, as power units for ships or for power generation in stationary facilities, the fuel - typically, as mentioned above, a heavy oil or other diesel fuel - is introduced by means of fuel injection nozzles in the combustion chamber. These injectors normally include a nozzle head partially projecting into the combustion chamber, also referred to as a nebulizer. The nozzle head is a wear part, which is subject to a high thermal, mechanical and chemical load collective. Depending on the degree of stress, damage to the nozzle head may occur, for example material removal as a result of corrosion, erosion and / or abrasion, or even cracks that can lead to breakup.
Die mechanischen Belastungen beruhen auch auf dem hohen Einspritzdruck, der über tausend bar betragen kann. Im Inneren des Düsenkopfs können Materialverluste durch Kavitation und / oder Erosion auftreten. Die thermischen Belastungen beruhen auf den hohen Temperaturen im Brennraum und den enormen Temperaturwechseln zwischen der Verbrennungstemperatur und der Temperatur der frisch zugeführten Spülluft. Auch im Inneren des Düsenkopfs, durch welches der Brennstoff eingebracht wird, führt das intermittierende Einspritzen zu schockartigen Temperaturwechseln. Die chemische Belastung des Düsenkopfs ist hauptsächlich in der Hochtemperatur- oder Heisskorrosion begründet. Die Heisskorrosion, die in erster Linie durch im Brennstoff enthaltenes Vanadium, Natrium und Schwefel verursacht wird, begünstigt die Materialabzehrung und Erosion. Insbesondere die Korrosion ist der Grund dafür, dass ein Düsenkopf bereits nach wenigen tausend Betriebsstunden unbrauchbar sein kann und ersetzt werden muss.The mechanical loads are also based on the high injection pressure, which can be over a thousand bar. Inside the nozzle head, material losses due to cavitation and / or erosion can occur. The thermal loads are based on the high temperatures in the Combustion chamber and the enormous temperature changes between the combustion temperature and the temperature of the freshly supplied purge air. Also in the interior of the nozzle head, through which the fuel is introduced, the intermittent injection leads to shock-like temperature changes. The chemical load of the nozzle head is mainly due to high temperature or hot corrosion. Hot corrosion, which is primarily caused by vanadium, sodium and sulfur contained in the fuel, promotes material degradation and erosion. In particular, the corrosion is the reason that a nozzle head can be unusable after a few thousand hours of operation and must be replaced.
Als Werkstoff für die Düsenköpfe in Grossdieselmotoren werden daher üblicherweise Stähle oder Legierungen auf Nickel- oder Cobalt-Basis, beispielsweise Stellite 6 verwendet. Mit der Cobalt-Basis-Legierung Stellite 6 lassen sich heute für Düsenköpfe in Grossdieselmotoren vertretbare Bauteilstandzeiten im Hinblick auf Erosion, Abrasion und Kavitation (insbesondere in den Bohrungen des Düsenkopfs) erreichen.As a material for the nozzle heads in large diesel engines therefore usually steels or alloys based on nickel or cobalt, such as
Dabei hat sich gezeigt, dass Legierungen mit hohem Chrom- und Nickelgehalt, bei welchen der Chrom- und Nickelgehalt z.B. um die 50%-Gewichtsprozent beträgt, aber vor allem auch Legierungen mit einem Chromgehalt von mehr als 50%- Gewichtsprozent, wie z.B. Cr/Ni 65/35 Legierungen, die mittels eines sogenannten HIP-Prozesses hergestellt werden, zwar sehr gute Eigenschaften in Bezug auf die oben erwähnten Probleme mit Hochtemperatur- oder Heisskorrosion haben. Solche Werkstoffe mit hohem Chrom-Gehalt und hervorragenden chemischen Eigenschaften in Bezug auf Hochtemperatur- und Heisskorrosion sind zum Beispiel bereits in der
In der
Obwohl der in der
So gehen gute Korrosionseigenschaften bestimmter Werkstoffe zum Beispiel zu Lasten der Härte. Zum Beispiel im Fall von Einspritzdüsen zum Einspritzen von Brennstoff, sind die Düsenkörper an sich gut gegen chemisch und physikalisch aggressive Umgebungen geschützt. Jedoch zeigen die Sitzflächen, mit denen zum Beispiel die Düsennadeln zusammenwirken, eine ungenügende Härte, was dazu führen kann, dass die entsprechenden Sitzflächen und / oder die Düsennadeln vorzeitig verschleissen, was zu Undichtigkeiten, Ungenauigkeiten bei der Treibstoffdosierung usw. führen kann.For example, good corrosion properties of certain materials are at the expense of hardness. For example, in the case of injectors for injecting fuel, the nozzle bodies themselves are well protected against chemically and physically aggressive environments. However, the seating surfaces with which, for example, the nozzle needles co-operate are insufficient in hardness, which can cause the respective seating surfaces and / or the nozzle needles to wear prematurely, which can lead to leaks, fuel metering inaccuracies, and the like.
Um Schäden am Motor insgesamt, einen durch den vorzeitigen Verschleiss des Einspritzventils erhöhten Treibstoffverbrauch oder zum Beispiel eine Erhöhung der Schadstoffe in den Verbrennungsgasen zu vermeiden, müssen die Einspritzdüsen oder zumindest deren betroffenen Komponenten frühzeitig ausgetauscht oder gewartet werden, was natürlich personal- und kostenintensiv ist und, wenn die Verschleissschäden nicht rechtzeitig erkannt werden, können diese Schäden vor allem im Fall von Hochseeschiffen zu einem erheblichen Sicherheitsrisiko werden.In order to avoid damage to the engine as a whole, increased by the premature wear of the injector fuel consumption or, for example, an increase in pollutants in the combustion gases, the injectors or at least their affected components must be replaced or maintained early, which is of course personnel and cost intensive and if the wear damage is not detected in time In the case of ocean-going vessels, these damages can be a significant security risk.
Im Prinzip können diese Probleme dadurch gelöst werden, dass die Sitzflächen mit einer geeigneten Beschichtung versehen werden, so dass der Sitzfläche durch die Beschichtung die geforderten physikalischen und / oder chemischen Eigenschaften vermittelt werden.In principle, these problems can be solved by providing the seating surfaces with a suitable coating so that the seating surface is given the required physical and / or chemical properties by the coating.
Allerdings steht bisher kein Verfahren zur Herstellung oder Beschichtung von Sitzflächen zur Verfügung, die tief unten in langen dünnen Bohrungen vorgesehen werden müssen.However, so far there is no method for the production or coating of seats available that must be provided deep down in long thin holes.
Zur Illustration des Problems soll anhand der
Die bekannte Einspritzdüse 31' der
Der Düsenkopf 301' weist eine Längsbohrung 305' auf und im Bereich seines unteren Endes mindestens ein Düsenloch 306', typischerweise z. B. fünf Düsenlöcher 306', die von der Längsbohrung 305' ausgehen und durch welche der Brennstoff in den Brennraum B' austreten kann.The nozzle head 301 'has a longitudinal bore 305' and in the region of its lower end at least one nozzle hole 306 ', typically z. B. five nozzle holes 306 ', from the longitudinal bore 305' go out and through which the fuel in the combustion chamber B 'can escape.
Im Innern des Düsenkörpers 300' ist ein Druckraum 307' vorgesehen, in welchen eine Zuführleitung 308' für den Brennstoff einmündet. Der Druckraum 307' wird in axialer Richtung von einem Ventilsitz 2' begrenzt. Ferner ist im Innern des Düsenkörpers 300' eine Düsennadel 7' angeordnet, die sich im Wesentlichen in Richtung der Längsachse A' erstreckt und die mit dem Ventilsitz 2' zusammenwirkt. In der in
Das Volumen zwischen dem Ventilsitz 2' und den Düsenlöchern 306' wird üblicherweise als Sackloch bezeichnet.The volume between the valve seat 2 'and the nozzle holes 306' is commonly referred to as a blind hole.
Die Längsbohrung 305' ist bei dem hier beschriebenen speziellen Beispiel als im wesentlichen zylindrische Bohrung ausgestaltet, die sich in Richtung der Längsachse A' erstreckt. Der Durchmesser d' der Längsbohrung 305' legt einen Strömungsquerschnitt fest, womit die für die Strömung des Brennstoffs zur Verfügung stehende Querschnittsfläche in der Längsbohrung 305' gemeint ist.The longitudinal bore 305 'is designed in the specific example described here as a substantially cylindrical bore which extends in the direction of the longitudinal axis A'. The diameter d 'of the longitudinal bore 305' defines a flow area, which means the available for the flow of the fuel cross-sectional area in the longitudinal bore 305 'is meant.
Die Düsennadel 7' ist in der Bohrung 4', die in
Der Abstand L' ist dabei typischerweise gross gegen den Durchmesser D' der Bohrung 4'. Das heisst, wenn im Rahmen der vorliegenden Anmeldung von einer langen dünnen Bohrung die Rede ist, dann ist damit eine Bohrung gemeint, deren Durchmesser klein im Vergleich zu einer für die Bohrung typischen bzw. wesentlichen Länge ist.The distance L 'is typically large against the diameter D' of the bore 4 '. That is, when in the context of the present application of a long thin bore is mentioned, then it is meant a bore whose diameter is small compared to a typical or typical for the bore length.
Im Beispiel einer Einspritzdüse gemäss
Das heisst, bei einer langen dünnen Bohrung im Sinne der vorliegenden Anmeldung beträgt der Durchmesser der Bohrung z.B. ca. 10% der massgeblichen Länge der Bohrung, wobei natürlich auch deutlich andere Verhältnisse von Durchmesser zu Bohrung möglich sind, je nachdem um welches Werkstück es sich handelt.That is, in a long thin bore in the context of the present application, the diameter of the bore is e.g. About 10% of the relevant length of the bore, which of course also significantly different ratios of diameter to bore are possible, depending on which workpiece it is.
An dem zuvor exemplarisch geschilderten Beispiel wird klar, dass es grundsätzlich schwierig ist, die Sitzfläche im Inneren einer langen dünnen Bohrung zu bearbeiten. Wenn die absoluten Abmessungen sogar z.B. im Bereich von nur wenigen Millimetern bis zu wenigen 10 Millimetern liegen, wie beim oben diskutierten Beispiel einer Einspritzdüse, ist ein Beschichten einer Sitzfläche tief im Inneren in einer so dünnen Bohrung bisher überhaupt nicht möglich.In the example described above by way of example, it is clear that it is basically difficult to machine the seat inside a long, thin bore. If the absolute dimensions are even e.g. ranging from only a few millimeters to a few 10 millimeters, as in the example of an injection nozzle discussed above, a coating of a seat deep inside in such a thin bore is not possible at all.
Die Aufgabe der Erfindung ist es daher, ein Verfahren zum Aufbringen einer Beschichtung auf einer Sitzfläche eines Werkstücks, sowie ein entsprechendes Werkstück vorzuschlagen, so dass die aus dem Stand der Technik bekannten Probleme mit den Sitzflächen des Werkstücks vermieden werden, und insbesondere höhere Standzeiten und damit kürzere Wartungsintervalle und letztlich auch eine höhere Betriebssicherheit erreicht wird.The object of the invention is therefore to propose a method for applying a coating to a seat surface of a workpiece, as well as a corresponding workpiece, so that the known from the prior art problems with the seat surfaces of the workpiece are avoided, and in particular higher service life and thus shorter maintenance intervals and ultimately a higher level of operational reliability is achieved.
Es wird somit speziell ein Verfahren bereitgestellt, mit welchem ein Werkstück, insbesondere eine Düse herstellbar ist, welche in einer dünnen und langen Bohrung, d.h. in einer im Verhältnis zum Durchmesser langen Bohrung, eine Beschichtung auf einer Sitzfläche aufweist. Eine weitere Aufgabe der Erfindung ist es, ein Verfahren bereitzustellen, mit welchem auf einer Sitzfläche in einer dünnen und langen Bohrung eine Beschichtung herstellbar ist. Insbesondere soll auch ein Verfahren zur Verfügung gestellt werden, mit welchem eine Sitzfläche in einer dünnen und langen Bohrung eines Werkstücks mit einer Beschichtung nachgerüstet werden kann. Darüber hinaus ist es eine Aufgabe der Erfindung, ein Werkstück, insbesondere einen Düsenkörper bereitzustellen, der in einer dünnen und langen Bohrung eine beschichtete Sitzfläche hat.It is thus provided in particular a method with which a workpiece, in particular a nozzle can be produced, which in a thin and long bore, ie in a relation to the diameter long bore, a coating on a seat surface. A further object of the invention is to provide a method with which a coating can be produced on a seating surface in a thin and long bore. In particular, a method is to be made available with which a seat in a thin and long bore of a workpiece can be retrofitted with a coating. Moreover, it is an object of the invention to provide a workpiece, in particular a nozzle body having a coated seat in a thin and long bore.
Die diese Aufgabe lösenden Gegenstände der Erfindung sind durch die Merkmale des unabhängigen Anspruchs der jeweiligen Kategorie gekennzeichnet.The objects of the invention solving this object are characterized by the features of the independent claim of the respective category.
Die abhängigen Ansprüche betreffen besonders vorteilhafte Ausführungsformen der Erfindung.The dependent claims relate to particularly advantageous embodiments of the invention.
Es wird somit ein Verfahren zum Aufbringen einer Beschichtung auf eine Sitzfläche eines Werkstücks vorgeschlagen, wobei die Sitzfläche innerhalb einer Bohrung im Werkstück in einem vorgegebenen Abstand von einer Eingangsöffnung der Bohrung vorgesehen wird. Erfindungsgemäss wird in einem vorgängigen Verfahrensschritt ein Beschichtungsmaterial auf die Sitzfläche aufgebracht und in einem weiteren Verfahrensschritt die Beschichtung auf der Sitzfläche mittels eines Energiestrahls ausgebildet, indem der Energiestrahl durch die Bohrung hindurch auf die Sitzfläche gerichtet wird.It is thus proposed a method for applying a coating to a seat surface of a workpiece, wherein the seat is provided within a bore in the workpiece at a predetermined distance from an inlet opening of the bore. According to the invention, a coating material is applied to the seat surface in a preceding process step, and in a further process step the coating is formed on the seat surface by means of an energy beam, by directing the energy beam through the bore onto the seat surface.
Durch das Verfahren der vorliegenden Erfindung ist es erstmals möglich, die Materialeigenschaften eines Basismaterials aus dem ein Werkstück, wie beispielsweise eine Einspritzdüse für einen Zweitakt-Grossdieselmotor gefertigt ist, völlig unabhängig von den Materialanforderungen zu wählen, die an eine zuverlässig funktionierende Sitzfläche tief im Inneren einer langen dünnen Bohrung im Werkstück gefordert sind.By the method of the present invention, it is possible for the first time to choose the material properties of a base material from which a workpiece, such as an injection nozzle for a two-stroke large diesel engine is made, completely independent of the material requirements are required to a reliably functioning seat deep inside a long thin bore in the workpiece.
Das wird dadurch erreicht, dass die Sitzfläche tief im Inneren der langen dünnen Bohrung mit einer Beschichtung versehen wird, deren Material je nach Anforderungen an die Eigenschaften der Sitzfläche frei wählbar ist.This is achieved by providing the seat deep inside the long thin bore with a coating whose material can be freely selected according to the requirements of the seat surface.
So kann für das Werkstück an sich z.B. ein Werkstoff auf einer Ni-Basis, einer Cr-Basislegierung, einer Cu-Basis- oder auf Grundlage einer Fe-Basislegierung gewählt werden, das verhältnismässig weich ist aber sehr gute Eigenschaften in Bezug auf Schutz gegen Heissgaskorrosion oder chemische Angriffe bietet. Als Beschichtungsmaterial für die Sitzfläche kann dann zum Beispiel ein deutlich härteres Material gewählt werden, so dass die Sitzfläche gegen permanente mechanische Belastungen besser gegen vorzeitigen Verschleiss z.B. durch Materialabtrag, Kavitation, Erosion, Mikroverschweissung oder Materialermüdung usw. geschützt ist.Thus, for the workpiece itself, e.g. a Ni-based, Cr-based, Cu-based or Fe-based alloy material which is relatively soft but offers very good protection against hot gas corrosion or chemical attack. As a coating material for the seat then, for example, a significantly harder material can be selected, so that the seat against permanent mechanical stress better against premature wear, for example. is protected by material removal, cavitation, erosion, micro-welding or material fatigue, etc.
In einem anderen Beispiel ist es auch möglich, dass die Beschichtung der Sitzfläche aus einem weicheren Material als das Werkstück an sich gefertigt ist, beispielweise um eine bessere Dichtigkeit an der Sitzfläche zu erreichen oder eine andere gewünschte Materialeigenschaft an der Sitzfläche zu realisieren oder aber es kann beispielsweise auch ein Material aus einer Metallmatrix mit eingelagerten Partikeln, deren Härte gleich oder höher als die der Metallmatrix ist, verwendet werden.In another example, it is also possible that the coating of the seat surface is made of a softer material than the workpiece itself, for example, to achieve a better seal on the seat or other or to realize another desired material property on the seat For example, a material of a metal matrix with embedded particles whose hardness is equal to or higher than that of the metal matrix, are used.
Auch andere Eigenschaften können durch die Beschichtung auf der Sitzfläche optimiert werden. Beispielsweise ist es möglich, dass die Sitzfläche selbst gegen andere korrosiv wirkende Prozesse geschützt werden muss, als z.B. eine Aussenwand des Werkstücks selbst, das einer anderen aggressiven Umgebung mit schädlichen Einwirkungen ausgesetzt wird.Other properties can be optimized by the coating on the seat. For example, it is possible that the seat itself must be protected against other corrosive processes, such as e.g. an outer wall of the workpiece itself, which is exposed to another aggressive environment with harmful effects.
Der Fachmann versteht sofort, dass die vorliegende Erfindung so flexibel ist, dass durch geeignete Wahl des Materials für die Beschichtung auf der Sitzfläche und / oder dadurch, dass beim Beschichtungsprozess selbst bestimmte Beschichtungsbedingungen gezielt ausgewählt werden, wie zum Beispiel die Energiedichte des Energiestrahls oder die Einwirkzeit des Energiestrahls während des Beschichtungsvorgangs, praktisch jede gewünschte Eigenschaft der Beschichtung auf der Sitzfläche gezielt eingestellt werden kann.The skilled person immediately understands that the present invention is so flexible that by suitable choice of the material for the coating on the Seat and / or the fact that the coating process itself certain coating conditions are selected specifically, such as the energy density of the energy beam or the action of the energy beam during the coating process, virtually any desired property of the coating on the seat can be selectively adjusted.
Das Beschichtungsmaterial wird dabei vor einem Energieeintrag durch den Energiestrahl, bevorzugt in Form eines Beschichtungspulvers und / oder in Form eines Beschichtungsdrahts, oder in Form von kleinen Stücken eines Beschichtungsdrahts und / oder in Form eines vorgefertigten Beschichtungskörpers zumindest auf einen Teil der Sitzfläche aufgebracht.The coating material is applied to an energy input by the energy beam, preferably in the form of a coating powder and / or in the form of a coating wire, or in the form of small pieces of a coating wire and / or in the form of a prefabricated coating body at least on a part of the seat.
Bei einem anderen Ausführungsbeispiel der Erfindung kann das Beschichtungsmaterial auch gleichzeitig mit einem Energieeintrag durch den Energiestrahl auf die Sitzfläche aufgebracht werden, d.h. es handelt sich um einen Spezialfall des an sich bekannten Auftragsschweissens.In another embodiment of the invention, the coating material may also be applied to the seating surface simultaneously with energy input by the energy beam, i. It is a special case of the well-known order welding.
Insbesondere zur Herstellung eines neuen Werkstücks, z.B. einer neuen Einspritzdüse für einen Zweitakt-Grossdieselmotor, kann nach der Ausbildung der Beschichtung auf der Sitzfläche durch die Beschichtung hindurch eine Funktionsbohrung eingebracht werden, durch die im Betriebszustand zum Beispiel Brennstoff transportiert werden kann.In particular for the production of a new workpiece, e.g. a new injection nozzle for a two-stroke large diesel engine, after the formation of the coating on the seat through the coating through a function hole can be introduced through which can be transported in the operating state, for example, fuel.
Besonders bevorzugt kommt als Energiestrahl ein Laserstrahl zur Verwendung, aber auch andere Energiestrahlen wie zum Beispiel ein Elektronenstrahl können in bestimmten Fällen vorteilhaft eingesetzt werden.Particularly preferably, a laser beam is used as the energy beam, but also other energy beams such as an electron beam can be used advantageously in certain cases.
Wie mehrfach erwähnt, ist die Sitzfläche in einem erfindungsgemässen Werkstück in einer langen dünnen Bohrung tief im Werkstück vorgesehen, wobei ein kleinster Durchmesser der Bohrung in einem Bereich zwischen der Eingangsöffnung und der Sitzfläche maximal 50% des Abstands, insbesondere maximal 25% des Abstands, und der kleinste Durchmesser der Bohrung bevorzugt maximal 10% des Abstands von der Eingangsöffnung beträgt.As mentioned several times, the seat is provided in a workpiece according to the invention in a long thin bore deep in the workpiece, wherein a smallest diameter of the bore in a region between the inlet opening and the seat maximum 50% of the distance, in particular not more than 25% of the distance, and the smallest diameter of the Bore preferably a maximum of 10% of the distance from the inlet opening amounts.
Dabei ist das Werkstück bevorzugt, aber nicht notwendig, ein Düsenkörper einer Düse, insbesondere eine Einspritzdüse eines Zweitakt-Grossdieselmotors, oder ein Sicherheitsventil oder ein Steuerventil für eine Komponente einer Einspritzanlage oder eine Schmierölbohrung in einem Zylindereinsatz.In this case, the workpiece is preferred, but not necessary, a nozzle body of a nozzle, in particular an injection nozzle of a two-stroke large diesel engine, or a safety valve or a control valve for a component of an injection system or a lubricating oil hole in a cylinder insert.
Als Beschichtungsmaterial kommt im Prinzip jedes Material in Frage, mit welchem sich eine gewünschte Eigenschaft der Beschichtung auf der Sitzfläche einstellen lässt. Bevorzugt kommt als Beschichtungsmaterial zum Beispiel eine Kobalt-Basislegierung, und / oder eine Chrom-Basislegierung und / oder eine Nickel-Basislegierung und / oder eine Eisen-Basislegierung in Frage.As a coating material is in principle any material in question, with which a desired property of the coating can be adjusted on the seat. For example, a cobalt-based alloy, and / or a chromium-based alloy and / or a nickel-based alloy and / or an iron-based alloy may be used as coating material.
Die Erfindung betrifft weiterhin ein Werkstück in welchem eine Sitzfläche innerhalb einer Bohrung in einem vorgegebenen Abstand von einer Eingangsöffnung der Bohrung vorgesehen ist, wobei auf der Sitzfläche eine Beschichtung ausgebildet ist, die mittels eines durch die Bohrung hindurch auf die Sitzfläche gerichteten Energiestrahls aus einem Beschichtungsmaterial hergestellt ist.The invention further relates to a workpiece in which a seat surface is provided within a bore at a predetermined distance from an entrance opening of the bore, wherein on the seat surface, a coating is formed, which made by means of a directed through the bore on the seat energy beam from a coating material is.
Im speziellen kann durch die Beschichtung hindurch eine Funktionsbohrung vorgesehen sein.In particular, a function bore can be provided through the coating.
Ein kleinster Durchmesser der Bohrung beträgt in einem Bereich zwischen der Eingangsöffnung und der Sitzfläche maximal 50% des Abstands, insbesondere maximal 25% des Abstands, und der kleinste Durchmesser der Bohrung kann bevorzugt maximal 10% des Abstandes der Sitzfläche von der Eingangsöffnung betragen.A smallest diameter of the bore is in a region between the inlet opening and the seat maximum 50% of the distance, in particular a maximum of 25% of the distance, and the smallest diameter of the bore may preferably not exceed 10% of the distance of the seat from the inlet opening amount.
Da die Eigenschaften der Beschichtung auf der Sitzfläche praktisch beliebig flexibel einstellbar sind, kann beispielsweise eine Härte der Beschichtung verschieden von einer Härte des Werkstücks und/ oder eine Korrosionsbeständigkeit der Beschichtung kann verschieden von einer Korrosionsbeständigkeit des Werkstücks und / oder jede andere Eigenschaft der Beschichtung kann sich von der entsprechenden Eigenschaft des Werksstücks unterscheiden.For example, as the coating properties on the seating surface are virtually arbitrarily flexibly adjustable, a hardness of the coating other than a hardness of the workpiece and / or a corrosion resistance of the coating may be different from a corrosion resistance of the workpiece and / or any other property of the coating differ from the corresponding characteristic of the workpiece.
Im Folgenden wird die Erfindung anhand der schematischen Zeichnung näher erläutert. Es zeigen:
- Fig. 1a - 1 c:
- ein erfindungsgemässes Verfahren zur Herstellung einer Beschichtung auf einer Sitzfläche;
- Fig. 2a - 2d:
- ein erfindungsgemässes Verfahren zur Nachrüstung einer Einspritzdüse mit einer Sitzflächenbeschichtung;
- Fig. 3a - 3d:
- ein erfindungsgemässes Verfahren zur Herstellung einer Einspritzdüse mit einer Sitzflächenbeschichtung.
- Fig. 1a - 1c:
- an inventive method for producing a coating on a seat surface;
- 2a-2d:
- an inventive method for retrofitting an injection nozzle with a seat surface coating;
- 3a-3d:
- an inventive method for producing an injection nozzle with a seat surface coating.
Anhand der
In einem vorgängigen Verfahrensschritt ist gemäss
Durch den Energieeintrag durch den Laserstrahl 6 wird das Beschichtungspulver 100 erhitzt, dadurch ganz oder teilweise angeschmolzen oder aufgeschmolzen, so dass sich schliesslich auf der Sitzfläche 2 die Beschichtung 2 ausbildet, z.B. aufgrund von Bildung einer schmelzmetallurgischen Verbindung oder eines Anhaftens der Schicht.In a previous process step is according to
By the energy input by the
In
Anhand der
In
Zur Anwendung eines erfindungsgemässen Verfahrens wurde gemäss
In
In
Anhand der
In
Damit im fertigen Zustand die Einspritzdüse 31 ihre Funktion erfüllen kann, wird gemäss
Schliesslich werden in den Düsenkopf 301 von aussen noch Düsenlöcher 306, wie in
Durch ein erfindungsgemässes Werkstück 3, zum Beispiel in Form einer Düse 31 können bisher nicht erreichbare Standzeiten realisiert werden, was insbesondere unter wirtschaftlichen Gesichtspunkten von grosser Bedeutung ist.By means of a
Der erfindungsgemässe Düsenkopf eignet sich einerseits somit unter anderem insbesondere für zukünftige Generationen von Grossdieselmotoren, die noch leistungsfähiger sind und noch höhere Anforderungen an die Belastbarkeit der Düsenköpfe stellen. Anderseits können auch bereits sich im Betrieb befindliche Komponenten gemäss der Erfindung nachgerüstet werden.On the one hand, the nozzle head according to the invention is therefore suitable, inter alia, in particular for future generations of large diesel engines, which are even more powerful and place even greater demands on the load capacity of the nozzle heads. On the other hand, already in-service components according to the invention can be retrofitted.
Dabei ist die Erfindung selbstverständlich nicht auf spezielle Anwendungen in Grossdieselmotoren beschränkt, sondern die Erfindung kann überall dort erfolgreich eingesetzt werden, wo in langen dünnen Bohrungen im Sinne der vorliegenden Erfindung Sitzflächen mit Beschichtungen versehen werden müssen, die bestimmte Funktionen zu erfüllen haben.Of course, the invention is not limited to special applications in large diesel engines, but the invention can be used successfully wherever long thin holes in the sense of present invention seating surfaces must be provided with coatings that have to fulfill certain functions.
Claims (13)
Priority Applications (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
EP20100152429 EP2228462B1 (en) | 2009-03-09 | 2010-02-02 | Method for applying a coating to a valve seat of a workpiece |
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
EP09154587 | 2009-03-09 | ||
EP20100152429 EP2228462B1 (en) | 2009-03-09 | 2010-02-02 | Method for applying a coating to a valve seat of a workpiece |
Publications (2)
Publication Number | Publication Date |
---|---|
EP2228462A1 true EP2228462A1 (en) | 2010-09-15 |
EP2228462B1 EP2228462B1 (en) | 2014-09-24 |
Family
ID=40825222
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
EP20100152429 Not-in-force EP2228462B1 (en) | 2009-03-09 | 2010-02-02 | Method for applying a coating to a valve seat of a workpiece |
Country Status (5)
Country | Link |
---|---|
EP (1) | EP2228462B1 (en) |
JP (1) | JP5481222B2 (en) |
KR (1) | KR20100101516A (en) |
CN (1) | CN101829650B (en) |
DK (1) | DK2228462T3 (en) |
Cited By (1)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
EP2604376B1 (en) * | 2011-12-16 | 2016-04-20 | Mitsubishi Heavy Industries, Ltd. | Overlay welding method and overlay welding apparatus |
Families Citing this family (4)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
JP5974379B2 (en) * | 2013-05-10 | 2016-08-23 | 株式会社Ihi | Uniflow scavenging 2-cycle engine |
EP2995795B1 (en) * | 2013-05-10 | 2019-07-10 | IHI Corporation | Uniflow scavenging 2-cycle engine |
CN104745999B (en) * | 2015-03-02 | 2017-03-08 | 安徽工业大学 | A kind of method and device of the endoporus hole wall impact spraying based on laser shock wave technology |
JP2019060251A (en) * | 2017-09-25 | 2019-04-18 | 日立オートモティブシステムズ株式会社 | High-pressure fuel supply device |
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EP0529208A1 (en) * | 1991-08-27 | 1993-03-03 | FUKUDA METAL FOIL & POWDER CO., LTD | Hard facing chromium-base alloys |
DE10038954A1 (en) * | 2000-08-09 | 2002-02-28 | Siemens Ag | Valve used as an injection valve for a common rail injection system comprises a valve body with a valve body seat, and a valve needle guided in the valve body with a valve needle seat to control an opening |
DE10163933A1 (en) * | 2001-12-22 | 2003-07-10 | Federal Mogul Friedberg Gmbh | Wire used for producing a wear-resistant surface coating for bearing surfaces of piston rings of I.C. engines is made from an iron- or a nickel-based material with alloying additions |
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JPH04123885A (en) * | 1990-09-11 | 1992-04-23 | Toyota Motor Corp | Cladding method by welding for valve seat parts of cylinder head |
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- 2010-01-15 KR KR1020100003912A patent/KR20100101516A/en active Search and Examination
- 2010-02-02 EP EP20100152429 patent/EP2228462B1/en not_active Not-in-force
- 2010-02-02 DK DK10152429T patent/DK2228462T3/en active
- 2010-02-16 JP JP2010031269A patent/JP5481222B2/en not_active Expired - Fee Related
- 2010-03-08 CN CN201010139518.5A patent/CN101829650B/en not_active Expired - Fee Related
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EP0529208A1 (en) * | 1991-08-27 | 1993-03-03 | FUKUDA METAL FOIL & POWDER CO., LTD | Hard facing chromium-base alloys |
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DE10163933A1 (en) * | 2001-12-22 | 2003-07-10 | Federal Mogul Friedberg Gmbh | Wire used for producing a wear-resistant surface coating for bearing surfaces of piston rings of I.C. engines is made from an iron- or a nickel-based material with alloying additions |
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Cited By (1)
Publication number | Priority date | Publication date | Assignee | Title |
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EP2604376B1 (en) * | 2011-12-16 | 2016-04-20 | Mitsubishi Heavy Industries, Ltd. | Overlay welding method and overlay welding apparatus |
Also Published As
Publication number | Publication date |
---|---|
KR20100101516A (en) | 2010-09-17 |
JP2010209464A (en) | 2010-09-24 |
CN101829650B (en) | 2015-11-25 |
JP5481222B2 (en) | 2014-04-23 |
EP2228462B1 (en) | 2014-09-24 |
DK2228462T3 (en) | 2014-12-08 |
CN101829650A (en) | 2010-09-15 |
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