EP2246457A1 - Method for roughening a metal surface, in particular a cylinder wall of a crankcase - Google Patents

Method for roughening a metal surface, in particular a cylinder wall of a crankcase Download PDF

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Publication number
EP2246457A1
EP2246457A1 EP10003319A EP10003319A EP2246457A1 EP 2246457 A1 EP2246457 A1 EP 2246457A1 EP 10003319 A EP10003319 A EP 10003319A EP 10003319 A EP10003319 A EP 10003319A EP 2246457 A1 EP2246457 A1 EP 2246457A1
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EP
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Prior art keywords
metal surface
roughening
flux
substance
mixture
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Granted
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EP10003319A
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German (de)
French (fr)
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EP2246457B1 (en
Inventor
Wolfram Dr. Wagener
Georg Bartholomie
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Bayerische Motoren Werke AG
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Bayerische Motoren Werke AG
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    • CCHEMISTRY; METALLURGY
    • C23COATING 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
    • C23CCOATING 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
    • C23C4/00Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
    • C23C4/02Pretreatment of the material to be coated, e.g. for coating on selected surface areas
    • CCHEMISTRY; METALLURGY
    • C23COATING 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
    • C23FNON-MECHANICAL REMOVAL OF METALLIC MATERIAL FROM SURFACE; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL; MULTI-STEP PROCESSES FOR SURFACE TREATMENT OF METALLIC MATERIAL INVOLVING AT LEAST ONE PROCESS PROVIDED FOR IN CLASS C23 AND AT LEAST ONE PROCESS COVERED BY SUBCLASS C21D OR C22F OR CLASS C25
    • C23F1/00Etching metallic material by chemical means
    • C23F1/10Etching compositions
    • C23F1/14Aqueous compositions
    • C23F1/32Alkaline compositions
    • C23F1/36Alkaline compositions for etching aluminium or alloys thereof

Definitions

  • the present invention relates to a method according to the preamble of claim 1.
  • Such a method is for example from EP 568315 B1 .
  • the methods described therein involve roughening cylinder surfaces of crankcases by irradiation with a high-pressure jet of pure water.
  • the cylinder surfaces are eroded by the high-pressure water jet, whereby soft structural phases are washed out of the surface.
  • the result of this erosion process is a rough surface with undercuts and channels compared to the initial state, which is then optimally suitable for a subsequent coating with a coating material, whereby the "undercuts" achieve a very good adhesion of the coating to the underlying material.
  • the object of the invention is to modify the known per se method for roughening metal surfaces so that it is cost-effective and feasible with less technical effort.
  • the basic principle of the invention is, instead of working with pure or essentially pure water, with a mixture of water and a substance which chemically reacts or "attacks" the metal surface to be roughened.
  • a high-pressure water jet takes place an additional, based on chemical processes roughening of the metal surface.
  • a very significant, resulting advantage is the fact that can be compared to the conventional method with lower pressures, thereby reducing the investment costs for the pump technology.
  • the pressure level of the high-pressure water jet can be lowered to 1000 to 2500 bar, without thereby worsening the "roughening performance” or “roughening quality" compared with conventional processes.
  • the metal surface is carefully freed from alkali residues after the roughening process.
  • the removal of lye residues can be done, for example, by rinsing at low pressure with pure water.
  • a "flux” may also be added to the water.
  • So-called fluxes are known from soldering. They are applied to the workpiece to achieve a good bond between the solder material and the material of the workpiece during soldering. This principle can also be used when roughening metal surfaces by means of a high-pressure water jet. After blasting the roughened metal surface and the drying and cooling of the surface remain residues of the water used for blasting added flux on the metal surface back.
  • the metal surface is coated after roughening by means of a thermal coating method.
  • a suitable, known coating method is, for example, the arc wire spraying method in which energy-rich metal particles are "shot" onto the surface to be coated by means of an arc. Due to the kinetic energy to be degraded upon impact of the metal particles or due to the local high pressures resulting there is a strong increase in temperature, which causes the flux residues with the material of the metal surface (eg aluminum or aluminum alloy) react chemically, which leads to a deoxidization of the metal surface and as a result to a low-oxide connection between the coating material (eg Fe alloys or Al alloys) and the material of the workpiece (eg aluminum).
  • the coating material eg Fe alloys or Al alloys
  • flux e.g. the flux produced by Solvay Fluor GmbH under the trade name "Nocoloc”.
  • the flux may be added to the water used for roughening in a concentration between e.g. 0.01% and 10% are added.
  • a dye may be added to the water used for roughening.
  • color pigments on the order of between 0.01 ⁇ m and 1 ⁇ m in a concentration of up to 15% can be added to the water. The addition of dye then makes it possible in a simple manner to control whether the lye added to the water or the flux added to the water has distributed uniformly over the metal surface to be roughened or roughened.

Abstract

The method comprises mechanically roughening a metal surface by spraying with a high-pressure liquid jet, where a mixture of water and substance is used as liquid and chemically reacts with the metal surface. The substance is lye and flux, where the lye concentration is 0.001-7% in relation to the mixture and the flux concentration is 0.01-10% in relation to the mixture. The high-pressure liquid jet has a pressure of 1000-2500 bar. After roughening the metal surface, the remaining of the substance added to the liquid is removed from the metal surface with pure water. The method comprises mechanically roughening a metal surface by spraying with a high-pressure liquid jet, where a mixture of water and substance is used as liquid and chemically reacts with the metal surface. The substance is lye and flux, where the lye concentration is 0.001-7% in relation to the mixture and the flux concentration is 0.01-10% in relation to the mixture. The high-pressure liquid jet has a pressure of 1000-2500 bar. After roughening the metal surface, the remaining of the substance added to the liquid is removed from the metal surface with pure water. After mechanical roughening, the flux remains on the roughened metal surface. The metal surface is provided with a surface coating using a thermal coating process after the roughening, where the metal surface passes to a chemical reaction of the flux remaining on the metal surface with the material of the metal surface at a temperature occurring on the metal surface for deoxidation of the metal surface and for oxidative connection between the coating material and the metal surface. The thermal coating process is plasma- or arc wire spraying process. A coloring material is added to the high-pressure liquid jet.

Description

Die vorliegende Erfindung betrifft ein Verfahren gemäß dem Oberbegriff des Patentanspruches 1.The present invention relates to a method according to the preamble of claim 1.

Ein derartiges Verfahren ist z.B. aus der EP 568315 B1 , US 5626674 oder der US 5380564 bekannt. Bei den dort beschriebenen Verfahren geht es darum, Zylinderlaufflächen von Kurbelgehäusen durch Bestrahlen mit einem Hochdruckstrahl aus reinem Wasser aufzurauhen. Die Zylinderlaufflächen werden durch den Hochdruckwasserstrahl erodiert, wobei weiche Gefügephasen aus der Oberfläche herausgewaschen werden. Ergebnis dieses Erosionsprozesses ist eine im Vergleich zum Ausgangszustand rauhe Oberfläche mit Hinterschneidungen und Kanälen, die dann optimal für eine anschließende Beschichtung mit einem Beschichtungsmaterial geeignet ist, wobei durch die "Hinterschneidungen" eine sehr gute Haftung der Beschichtung auf dem darunter befindlichen Material erreicht wird.Such a method is for example from EP 568315 B1 . US 5626674 or the US 5380564 known. The methods described therein involve roughening cylinder surfaces of crankcases by irradiation with a high-pressure jet of pure water. The cylinder surfaces are eroded by the high-pressure water jet, whereby soft structural phases are washed out of the surface. The result of this erosion process is a rough surface with undercuts and channels compared to the initial state, which is then optimally suitable for a subsequent coating with a coating material, whereby the "undercuts" achieve a very good adhesion of the coating to the underlying material.

Die in den oben genannten Dokumenten beschriebenen Verfahren arbeiten, wie bereits erwähnt, mit reinem Wasser. Aufgrund der hohen kinetischen Energie mit der der Hochdruckwasserstrahl auf die Zylinderlaufflächen auftrifft, erwärmt sich das Kurbelgehäuse auf eine Temperatur im Bereich zwischen 50°C und 90°C, wobei das Wasser zumindest teilweise verdampft. Um den Wasserstrahl hinreichend stark zu beschleunigen, so dass die Zylinderlaufflächen bis in eine Tiefe von 50-100 µm "zerfurcht" werden, ist ein sehr hoher Pumpendruck und ein in Relation zu dem Druckniveau großer Volumenstrom erforderlich.The methods described in the above documents work, as already mentioned, with pure water. Due to the high kinetic energy with which the high pressure water jet impinges on the cylinder surfaces, the crankcase heats up to a temperature in the range between 50 ° C and 90 ° C, wherein the water at least partially evaporated. To accelerate the water jet sufficiently strong, so that the cylinder surfaces are "ruffled" to a depth of 50-100 microns, is a very high pump pressure and a large volume flow in relation to the pressure level required.

Derzeit bieten nur einige wenige Pumpenhersteller Pumpen an, welche die erforderlichen Drücke von 2500 - 3500 bar bei einem Volumenstrom von 10 - 25 Liter/min erzeugen können. Dementsprechend teuer ist nicht nur die Pumpentechnik an sich, sondern auch die Wiederaufbereitung des Volumens des verwendeten Wassers. Zur Herausfilterung der erosiv abgetragenen Metallpartikel aus dem Wasser werden nämlich Filter benötigt, die Partikel in der Größenordnung von einem Durchmesser von 1 µm herausfiltern können.Currently, only a few pump manufacturers offer pumps that can produce the required pressures of 2500 - 3500 bar at a flow rate of 10 - 25 liters / min. Accordingly expensive is not only the pump technology itself, but also the reprocessing of the volume of water used. To filter out the erosively removed metal particles from the water namely filters are needed that can filter out particles on the order of a diameter of 1 micron.

Aufgabe der Erfindung ist es, das an sich bekannte Verfahren zum Aufrauhen von Metalloberflächen so zu modifizieren, dass es kostengünstiger und mit einem geringeren technischen Aufwand durchführbar ist.The object of the invention is to modify the known per se method for roughening metal surfaces so that it is cost-effective and feasible with less technical effort.

Das Grundprinzip der Erfindung besteht darin, anstatt mit reinem oder im Wesentlichen reinem Wasser mit einem Gemisch aus Wasser und einer Substanz zu arbeiten, die mit der aufzurauhenden Metalloberfläche chemisch reagiert bzw. diese "angreift". Zusätzlich zu einer rein mechanischen, d.h. erosiven bzw. abrasiven Aufrauhung mittels eines Hochdruckwasserstrahls erfolgt eine zusätzliche, auf chemischen Vorgängen beruhende Aufrauhung der Metalloberfläche. Ein ganz wesentlicher, sich hieraus ergebender Vorteil ist darin zu sehen, dass im Vergleich zu den herkömmlichen Verfahren mit geringeren Drücken gearbeitet werden kann, wodurch sich die Investitionskosten für die Pumpentechnik verringern. Je nach Art und Konzentration der dem Wasser zugegebenen Substanz kann das Druckniveau des Hochdruckwasserstrahls auf 1000 bis 2500 bar abgesenkt werden, ohne dass sich dadurch die "Aufrauhleistung" bzw. "Aufrauhqualität" gegenüber herkömmlichen Verfahren verschlechtert.The basic principle of the invention is, instead of working with pure or essentially pure water, with a mixture of water and a substance which chemically reacts or "attacks" the metal surface to be roughened. In addition to a purely mechanical, i. erosive or abrasive roughening by means of a high-pressure water jet takes place an additional, based on chemical processes roughening of the metal surface. A very significant, resulting advantage is the fact that can be compared to the conventional method with lower pressures, thereby reducing the investment costs for the pump technology. Depending on the nature and concentration of the substance added to the water, the pressure level of the high-pressure water jet can be lowered to 1000 to 2500 bar, without thereby worsening the "roughening performance" or "roughening quality" compared with conventional processes.

Sehr gute Ergebnisse lassen sich erzielen, wenn dem verwendeten Wasser beispielsweise Natronlauge (NaOH) zugesetzt wird, z.B. in einer Konzentration, mit der sich ein Laugenanteil im Bereich zwischen 0,001 % bis 7 % des Gesamtgemischs ergibt.Very good results can be obtained if, for example, sodium hydroxide solution (NaOH) is added to the water used, for example in a concentration, with which a caustic content in the range between 0.001% to 7% of the total mixture results.

Nach einer Weiterbildung der Erfindung wird die Metalloberfläche nach dem Aufrauhvorgang sorgfältig von Laugenrückständen befreit. Die Entfernung von Laugenrückständen kann beispielsweise durch Abspülen mit niedrigem Druck mit reinem Wasser erfolgen.According to a development of the invention, the metal surface is carefully freed from alkali residues after the roughening process. The removal of lye residues can be done, for example, by rinsing at low pressure with pure water.

Alternativ oder ergänzend zur Zugabe einer Lauge kann dem Wasser auch ein "Flussmittel" zugesetzt werden. Sogenannte Flussmittel sind aus der Löttechnik bekannt. Sie werden auf das Werkstück aufgetragen, um beim Löten eine gute Verbindung zwischen dem Lotmaterial und dem Material des Werkstücks zu erreichen. Dieses Prinzip kann auch beim Aufrauhen von Metalloberflächen mittels eines Hochdruckwasserstrahls eingesetzt werden. Nach dem Abstrahlen der aufzurauhenden Metalloberfläche und der Trocknung und Abkühlung der Oberfläche verbleiben Reste des dem zum Abstrahlen verwendeten Wassers zugesetzten Flussmittels auf der Metalloberfläche zurück.Alternatively or in addition to the addition of an alkali, a "flux" may also be added to the water. So-called fluxes are known from soldering. They are applied to the workpiece to achieve a good bond between the solder material and the material of the workpiece during soldering. This principle can also be used when roughening metal surfaces by means of a high-pressure water jet. After blasting the roughened metal surface and the drying and cooling of the surface remain residues of the water used for blasting added flux on the metal surface back.

Nach einer Weiterbildung der Erfindung wird die Metalloberfläche nach dem Aufrauhen mittels eines thermischen Beschichtungsverfahrens beschichtet. Ein geeignetes, bekanntes Beschichtungsverfahren ist z.B. das Lichtbogendrahtspritzverfahren, bei dem mittels eines Lichtbogens energiereiche Metallpartikel auf die zu beschichtende Oberfläche "geschossen" werden. Aufgrund der beim Auftreffen der Metallpartikel abzubauenden kinetische Energie bzw. aufgrund der hierbei lokal entstehenden hohen Drücke kommt es zum einem starken Temperaturanstieg, was dazu führt, dass die Flussmittelrückstände mit dem Material der Metalloberfläche (z.B. Aluminium bzw. Aluminium-Legierung) chemisch reagieren, was zu einer Entoxidierung der Metalloberfläche und im Ergebnis zu einer oxidarmen Verbindung zwischen dem Beschichtungsmaterial (z.B. Fe-Legierungen oder Al-Legierungen) und dem Material des Werkstücks (z.B. Aluminium) führt.According to a development of the invention, the metal surface is coated after roughening by means of a thermal coating method. A suitable, known coating method is, for example, the arc wire spraying method in which energy-rich metal particles are "shot" onto the surface to be coated by means of an arc. Due to the kinetic energy to be degraded upon impact of the metal particles or due to the local high pressures resulting there is a strong increase in temperature, which causes the flux residues with the material of the metal surface (eg aluminum or aluminum alloy) react chemically, which leads to a deoxidization of the metal surface and as a result to a low-oxide connection between the coating material (eg Fe alloys or Al alloys) and the material of the workpiece (eg aluminum).

Als "Flussmittel" kann z.B. das von der Solvay Fluor GmbH unter dem Markennamen "Nocoloc" hergestellte Flussmittel verwendet werden. Das Flussmittel kann dem zum Aufrauhen verwendeten Wasser in einer Konzentration zwischen z.B. 0,01 % und 10 % zugegeben werden.As a "flux", e.g. the flux produced by Solvay Fluor GmbH under the trade name "Nocoloc". The flux may be added to the water used for roughening in a concentration between e.g. 0.01% and 10% are added.

Dem zum Aufrauhen verwendeten Wasser kann ferner ein Farbstoff zugegeben werden. Beispielsweise können Farbpigmente in einer Größenordnung zwischen 0,01 µm und 1 µm in einer Konzentration von bis zu 15 % dem Wasser zugegeben werden. Die Zugabe von Farbstoff ermöglicht dann in einfacher Weise eine Kontrolle, ob sich die dem Wasser zugesetzte Lauge bzw. das dem Wasser zugesetzte Flussmittel gleichmäßig auf der aufzurauhenden bzw. aufgerauhten Metalloberfläche verteilt hat.Further, a dye may be added to the water used for roughening. For example, color pigments on the order of between 0.01 μm and 1 μm in a concentration of up to 15% can be added to the water. The addition of dye then makes it possible in a simple manner to control whether the lye added to the water or the flux added to the water has distributed uniformly over the metal surface to be roughened or roughened.

Claims (12)

Verfahren zum Aufrauhen einer Metalloberfläche, insbesondere einer Zylinderwandung eines Kurbelgehäuses, wobei die Metalloberfläche durch Besprühen mit einem Hochdruckflüssigkeitsstrahl mechanisch aufgerauht wird,
dadurch gekennzeichnet, dass als Flüssigkeit ein Gemisch aus Wasser und einer Substanz verwendet wird, das bzw. die mit der Metalloberfläche chemisch reagiert.
Method for roughening a metal surface, in particular a cylinder wall of a crankcase, wherein the metal surface is mechanically roughened by spraying with a high-pressure liquid jet,
characterized in that a mixture of water and a substance which reacts chemically with the metal surface is used as the liquid.
Verfahren nach Anspruch 1,
dadurch gekennzeichnet, dass es sich bei der Substanz um eine Lauge handelt.
Method according to claim 1,
characterized in that the substance is an alkali.
Verfahren nach Anspruch 2,
dadurch gekennzeichnet, dass es sich bei der Lauge um eine Natronlauge (NaOH), insbesondere um konzentrierte Natronlauge, handelt.
Method according to claim 2,
characterized in that the lye is a sodium hydroxide solution (NaOH), in particular concentrated sodium hydroxide solution.
Verfahren nach einem der Ansprüche 1 bis 3,
dadurch gekennzeichnet, dass die Laugenkonzentration in Bezug auf das Gemisch im Bereich zwischen 0,001 % und 7 % liegt.
Method according to one of claims 1 to 3,
characterized in that the lye concentration with respect to the mixture ranges between 0.001% and 7%.
Verfahren nach einem der Ansprüche 1 bis 4,
dadurch gekennzeichnet, dass der Hochdruckflüssigkeitsstrahl einen Druck von bis zu 3500 bar, insbesondere einen Druck im Bereich zwischen 1000 bar und 2500 bar aufweist.
Method according to one of claims 1 to 4,
characterized in that the high-pressure liquid jet has a pressure of up to 3500 bar, in particular a pressure in the range between 1000 bar and 2500 bar.
Verfahren nach einem der Ansprüche 1 bis 5,
dadurch gekennzeichnet, dass nach dem Aufrauhen der Metalloberfläche Reste der dem Wasser zugesetzten Substanz mit reinem Wasser von der Metalloberfläche entfernt werden.
Method according to one of claims 1 to 5,
characterized in that after roughening the metal surface residues of the water added substance are removed with pure water from the metal surface.
Verfahren nach einem der vorangehenden Ansprüche,
dadurch gekennzeichnet, dass es sich bei der Substanz um ein Flussmittel handelt.
Method according to one of the preceding claims,
characterized in that the substance is a flux.
Verfahren nach Anspruch 7,
dadurch gekennzeichnet, dass die Flussmittelkonzentration in Bezug auf das Gemisch im Bereich zwischen 0,01 % und 10 % liegt.
Method according to claim 7,
characterized in that the flux concentration with respect to the mixture ranges between 0.01% and 10%.
Verfahren nach einem der Ansprüche 7 oder 8,
dadurch gekennzeichnet, dass nach dem mechanischen Aufrauhen Flussmittel auf der aufgerauhten Metalloberfläche zurückbleibt.
Method according to one of claims 7 or 8,
characterized in that after mechanical roughening, flux remains on the roughened metal surface.
Verfahren nach einem der vorangehenden Ansprüche,
dadurch gekennzeichnet, dass die Metalloberfläche nach dem Aufrauhen mittels eines thermischen Beschichtungsverfahrens mit einer Oberflächenbeschichtung versehen wird, wobei es bei der hierbei an der Metalloberfläche auftretenden Temperatur zu einer chemischen Reaktion des auf der Metalloberfläche verbliebenen Flussmittels mit dem Werkstoff der Metalloberfläche kommt, insbesondere zu einer Entoxidierung der Metalloberfläche und zu einer oxidarmen Verbindung zwischen dem Beschichtungsmaterial und der Metalloberfläche.
Method according to one of the preceding claims,
characterized in that the surface of the metal after roughening by means of a thermal coating process is provided with a surface coating, wherein it occurs at the temperature occurring here at the metal surface to a chemical reaction of the remaining on the metal surface flux with the material of the metal surface, in particular to a deoxidation the metal surface and an oxide-poor connection between the coating material and the metal surface.
Verfahren nach Anspruch 10,
dadurch gekennzeichnet, dass als Beschichtungsverfahren Laserspritzen zum Einsatz kommt, insbesondere ein thermisches Beschichtungsverfahren wie das Plasma- oder Lichtbogendrahtspritzen.
Method according to claim 10,
characterized in that as a coating method laser spraying is used, in particular a thermal coating method such as plasma or arc wire spraying.
Verfahren nach einem der Ansprüche 1 bis 11,
dadurch gekennzeichnet, dass dem Hochdruckflüssigkeitsstrahl ein Farbstoff zugesetzt wird.
Method according to one of claims 1 to 11,
characterized in that a dye is added to the high-pressure liquid jet.
EP10003319.0A 2009-04-30 2010-03-27 Method for roughening a metal surface, in particular a cylinder wall of a crankcase Active EP2246457B1 (en)

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Application Number Priority Date Filing Date Title
DE102009019674.9A DE102009019674B4 (en) 2009-04-30 2009-04-30 Process for coating a cylinder wall of a crankcase

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EP2246457A1 true EP2246457A1 (en) 2010-11-03
EP2246457B1 EP2246457B1 (en) 2017-12-06

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WO2015032461A1 (en) * 2013-09-05 2015-03-12 Bayerische Motoren Werke Aktiengesellschaft Method for machining a cylinder wall of an internal combustion engine
CN105555987A (en) * 2013-09-05 2016-05-04 宝马股份公司 Method for machining a cylinder wall of an internal combustion engine
US20160208370A1 (en) * 2013-09-05 2016-07-21 Bayerische Motoren Werke Aktiengesellschaft Method for machining a cylinder wall of an internal combustion engine
US10214803B2 (en) 2013-09-05 2019-02-26 Bayérische Motoren Werke Aktiengesellschaft Method for machining a cylinder wall of an internal combustion engine
EP3132893A1 (en) * 2015-08-20 2017-02-22 Sturm Maschinen- & Anlagenbau GmbH Method and apparatus for machining and roughening a surface

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DE102009019674B4 (en) 2016-09-01
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