EP2533911B1 - Method for removing overspray of thermal spray coatings - Google Patents

Method for removing overspray of thermal spray coatings Download PDF

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Publication number
EP2533911B1
EP2533911B1 EP11703825.7A EP11703825A EP2533911B1 EP 2533911 B1 EP2533911 B1 EP 2533911B1 EP 11703825 A EP11703825 A EP 11703825A EP 2533911 B1 EP2533911 B1 EP 2533911B1
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EP
European Patent Office
Prior art keywords
jet
overspray
lance
angle
plane
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EP11703825.7A
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German (de)
French (fr)
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EP2533911A1 (en
Inventor
Wolfgang Treutmann
Gerhard Flores
Clemens Maria Verpoort
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Ford Werke GmbH
Gehring Technologies GmbH and Co KG
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Ford Werke GmbH
Gehring Technologies GmbH and Co KG
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Publication of EP2533911A1 publication Critical patent/EP2533911A1/en
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B08—CLEANING
    • B08B—CLEANING IN GENERAL; PREVENTION OF FOULING IN GENERAL
    • B08B3/00—Cleaning by methods involving the use or presence of liquid or steam
    • B08B3/02—Cleaning by the force of jets or sprays
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B08—CLEANING
    • B08B—CLEANING IN GENERAL; PREVENTION OF FOULING IN GENERAL
    • B08B3/00—Cleaning by methods involving the use or presence of liquid or steam
    • B08B3/02—Cleaning by the force of jets or sprays
    • B08B3/024—Cleaning by means of spray elements moving over the surface to be cleaned
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B24—GRINDING; POLISHING
    • B24C—ABRASIVE OR RELATED BLASTING WITH PARTICULATE MATERIAL
    • B24C3/00—Abrasive blasting machines or devices; Plants
    • B24C3/32—Abrasive blasting machines or devices; Plants designed for abrasive blasting of particular work, e.g. the internal surfaces of cylinder blocks

Definitions

  • the properties of functional surfaces can be adjusted and improved by coating, in particular by thermal coating.
  • thermal coating the spray material supplied as wire or powder is melted in the process, so that individual particles (droplets) in the liquid or doughy state are moved in the spray jet against the substrate. Due to the different particle size, a core jet with completely molten particles and two-sided marginal rays with only partially melted particles, which extend at a certain opening angle to the core beam. The actual coating takes place with the core jet.
  • the edge rays leave the functional surface and sit down outside the functional area on the workpiece and form there undesirable adhesions. These adhesions are referred to as overspray below.
  • the overspray is undesirable because it can become detached from the workpiece during operation of the motor. The resulting uncontrolled particles enter the oil circuit and cause increased wear or even the total failure of the engine.
  • the workpieces are often masked so that the adjacent surface can not be coated.
  • the required masks must be done by hand be attached to the intended locations of the workpiece. Therefore, the masking is very complex and so far not automatable. The thermal spraying of cylinder bores could therefore prevail only in the small series production.
  • a high-pressure water jet is directed more or less vertically or diffusely onto the layer to be ablated.
  • the kinetic energy of the water jet causes the destruction of the adherent layer and, as a result, the removal of the layer.
  • the water jet can be positioned with high precision and allows a targeted local removal in the desired areas.
  • the disadvantage of the known hydromechanical removal methods is the high operating pressures of the water jet systems, which are reported in the literature as 150 MPa to 400 MPa.
  • the surface of the workpiece in the region of the overspray-coated edge zone can be changed inadmissibly or even damaged.
  • the functional layer In order to prevent the functional layer from being damaged by the high-pressure water jet, in some cases the functional layer has to be protected by masks from the high-pressure water jet, with the above-mentioned disadvantages.
  • the high pressure water jetting causes a high energy demand for the Operation of the system and requires a very expensive equipment.
  • the object underlying the invention is to provide a method which allows the process-reliable removal of overspray on the surfaces adjacent to the bore, thereby largely overcoming the disadvantages known from the prior art.
  • the method should be suitable for large series, which requires complete automation with simultaneously low energy costs and high process reliability.
  • This object is achieved by a method for removing the overspray of a sprayed onto a workpiece layer in which at least one liquid jet of a jet lance is directed to the overspray provided areas of the workpiece, wherein the at least one liquid jet at an angle less than 90 °, preferably less than 60 ° and more preferably less than 30 ° and greater than 5 °.
  • the method according to the invention makes use of the knowledge that the surfaces of the workpiece adjoining the actual functional surface were not specially prepared for the application of a layer, so that the droplets or the particles adhere to the workpiece less intensively than on the actual functional surface of the workpiece Case is.
  • the coating as already mentioned, takes place through the core jet with completely melted droplets.
  • Another effect that degrades the adhesion conditions between overspray and the surface of the substrate is to be seen in the fact that the droplets must cover a further path until they impinge on the region of the workpiece adjacent to the functional surface. As a result, the droplets cool more strongly, which further reduces their adhesion to the workpiece surface.
  • This realization makes the invention Benefit method by the liquid jet at the lowest possible angle, which should be as small as possible to achieve a good peeling effect, directed to the surface of the workpiece.
  • angles of less than 30 °, preferably less than 20 ° and more preferably less than 10 °, have proven suitable.
  • the liquid jet acts more or less parallel to the contact surface between substrate and coating.
  • the peeling effect according to the invention is assisted if the liquid jet is to some extent externally, i. H. is guided by the uncoated workpiece surface in the direction of the overspray-prone areas of the workpiece surface. As a result, the overspray is replaced by "peeling" instead of "smashing".
  • the liquid jet acts like a hydrodynamic wedge, which slides in the parting plane between the substrate or the surface of the workpiece and the sprayed-on layer (overspray). This significantly simplifies the removal of the overspray.
  • the working pressure of the liquid jet can be significantly reduced, which has a positive effect on the energy requirements and thus also on the operating costs.
  • the jet lance and / or the outlet direction of the at least one liquid jet from the jet lance is controlled in dependence on the orientation of the surface of the workpiece in the areas provided with overspray.
  • the jet lance executes a rotational movement.
  • a first angle ⁇ includes, and that the first angle ⁇ is greater than 5 ° and less than 85 °.
  • the direction of at least one liquid jet with a plane (XY plane), which is arranged perpendicular to a Z-axis of the jet lance, a second angle ⁇ includes, and that the second angle greater than 5 ° and less than 85 °.
  • At least one nozzle of the jet lance is pivotable in such a way that the first angle ⁇ and the second angle ⁇ in each case in ranges between 5 ° and 85 ° are adjustable. This makes it possible that the spray jet of the jet lance always impinges on the surface of the workpiece at approximately equal angles.
  • a cooling lubricant preferably a water-miscible cooling lubricant
  • the concentrate of this mixture is selected so that a mineral oil-containing emulsion or a synthetic mineral oil-free solution is available as a fluid.
  • This cooling lubricant has the advantage that it cools the previously heated during thermal coating workpiece and in particular its functional surface (cylinder bore). This allows the workpiece to be processed better and faster in the downstream machining processes.
  • This cooling lubricant also has the advantage that it is not corrosive and thus no corrosion occurs on the treated with the inventive process workpieces.
  • cooling lubricants are also used in the downstream processes, such as honing or chamfering the cylinder bore.
  • this cooling lubricant is firstly already available and there is no need to separate the liquids for removing the overspray from the cooling lubricants in the downstream processes. This results in a considerable simplification in the process management.
  • only one reconditioning and pumping device is needed for the entire production line.
  • the cooling lubricant with a pressure in a range between 15 MPa and 60 MPa, preferably in a range between 20 MPa and 50 MPa, and particularly preferably in a range between 25 MPa and 40 MPa, the or Nozzles, which the Liquid jet form, is supplied.
  • These pressure ranges are significantly lower than the pressures referred to in the prior art for conventional high pressure water jetting. From the lower operating pressures result in considerable advantages in terms of energy requirements, but also the structural design of the jet device according to the invention can be significantly simplified. In addition, the risk of accidents due to the lower operating pressures and the associated lower kinetic energy of the liquid jet is lower.
  • the pressure with which the cooling lubricant is supplied to the nozzles of the jet lance is controlled as a function of the rotational and / or translational position of the nozzles can be.
  • the control of the pressure is a way to specifically apply pressure to places where the overspray adheres particularly vigorously to a higher kinetic energy of the liquid jet, in order to achieve an optimal removal result in this way.
  • the pressure can also be lowered if the overspray is very easily removable in a certain area.
  • the method according to the invention is part of a production chain and of course is only used when one or more functional surfaces has been provided with a coating, for example by thermal spraying. Then, the method according to the invention can be used directly afterwards to remove the overspray. In this case, the liquid jet also causes a cooling of the workpiece, especially when using aqueous liquids.
  • the workpiece temperature can be above 100 ° C and a subsequent honing operation for reasons of dimensional accuracy a workpiece temperature of max. 25 ° C required. Then the previously coated functional surface can be honed and, if necessary, beveled with the edges of the honed functional surface.
  • the coated functional surface it is also possible for the coated functional surface to be actively or passively cooled, for example with a water-based coolant (cooling lubricant), and then honed. Following honing, the overspray is removed by the method according to the invention and finally the edges of the honed functional surface are provided with a chamfer.
  • a water-based coolant cooling lubricant
  • a jet lance for performing one of the preceding methods for complete or partial removal of overspray
  • the jet lance comprises a receptacle, at least one cooling lubricant connection and at least one nozzle, wherein the at least one nozzle of the jet lance with one of the axis of rotation of the jet lance and a radius plane spanned plane (ZR plane), a first angle ⁇ includes, and wherein the first angle ⁇ is greater than 5 ° and less than 85 °.
  • the at least one nozzle of the jet lance with a plane (XY plane), which is arranged perpendicular to the rotation axis (Z axis), a second angle ⁇ include, wherein the second angle ⁇ according to the invention> 5 ° and ⁇ 85 ° is.
  • a jet lance allows the angle between the liquid jet and the surface of the Set workpiece according to the method according to the invention.
  • the at least one nozzle of the jet lance is pivotable, so that the first angle ⁇ and / or the second angle ⁇ is adjustable.
  • the pivoting device of the at least one nozzle can be controlled by a numerical control, so that during the processing of the liquid jet can always be aligned so that it occurs as possible at a shallow angle to the workpiece surface.
  • the nozzles can be individually switched on and switched off. These switching operations can also take place during the operation of the jet lance, so that even in this way an optimized beam guidance with regard to the energy and fluid requirements is possible despite fixed nozzles.
  • the nozzles in the longitudinal direction of Z-axis of the jet lance are arranged spaced from each other, so that at both ends of the coated functional surfaces of the overspray can be removed simultaneously.
  • FIG. 1 is a cylinder block 1, which is also referred to below as a workpiece or substrate, shown with a piston barrel 3 in longitudinal section.
  • a coating 5 is applied by thermal spraying. After honing, this coating forms a functional surface which is optimized with regard to wear and oil consumption of the internal combustion engine.
  • the piston raceway 3 ends in FIG. 1 at the top of the so-called top surface 7, on which later the cylinder head gasket and the cylinder head are placed (not shown).
  • the cylinder block 1 goes into the crankcase. It is of importance for the invention that the contour of the cylinder block 1 has projections, recesses and other "irregularities" underneath the piston raceway 3.
  • FIG. 1 At the bottom of the FIG. 1 are given three coordinate axes X, Y and Z of a Cartesian stationary coordinate system.
  • the Z-axis is congruent with the longitudinal axis of the piston raceway 3 and a rotation axis of a jet lance 9 according to the invention.
  • the jet lance 9 rotates, as indicated by an arrow 11, about the Z-axis.
  • an R-axis is entered at the jet lance, which extends in the direction of a radius jet and is fixedly connected to the jet lance 9. So it makes the rotational movement of the jet lance 9 with.
  • the coating of the piston raceway 3 takes place in that a suitably formed lance (not shown) is introduced in the direction of the Z-axis in the piston raceway and thereby the protective layer 5 is sprayed onto the piston raceway 3.
  • the lance moves on the one hand in the direction of the Z-axis and simultaneously rotates about the Z-axis. Meanwhile, a jet of melted occurs Material which forms the layer 5, radially from the lance and is blown with high kinetic energy to the piston raceway 3.
  • the surface of the piston barrel 3 is prepared and degreased for this purpose. This results in a very intimate and permanent connection between the layer 5 and the actual piston barrel 3.
  • the adhesion of the overspray 13 is less good than the adhesion of the layer 5 on the piston raceway 3.
  • the jet travels from the jet lance to hitting, for example, on the lower portions of the cylinder block 1 at.
  • the overspray adheres less well to the surface of the workpiece 1 than the layer 5 on the piston raceway 3.
  • the overspray 13 must be removed from the workpiece 1, otherwise it will fail during operation of the workpiece Solve internal combustion engine and could get into the oil circuit of the internal combustion engine. This can result in increased wear or major consequential damage. Also in the area of the top surface 7 of the overspray 13 must be removed, since the cylinder head gasket can only be placed when the top surface 7 is flat and has no jarring in the form of overspray 13 more.
  • a second angle ⁇ between the liquid jet 15 and the top surface 7 is significantly smaller than 90 °, it is about 30 ° to 40 °.
  • a first angle ⁇ which indicates the angle between a plane defined by the axis of rotation (Z axis) and a plane spanned by the R axis, is not visible in the figures and is therefore not registered.
  • the liquid jet 15 does not occur perpendicularly to the overspray 13, but if possible impinges on the workpiece surface at a small angle, that is to say flat. This ensures that the liquid jet 15 penetrates to a certain extent like a wedge between the overspray 13 and the top surface 7 and thereby the overspray is peeled off from the top surface 7. As a result, the speed at which the overspray 13 is removed is significantly increased and a relatively low operating pressure of, for example, 28 MPa is sufficient to ensure a reliable and rapid removal of the overspray.
  • the angle at which the liquid jet 15 strikes the surface of the workpiece 1 is determined by the first angle ⁇ and the second angle ⁇ .
  • the jet lance 9 must be positioned so far above the top surface 7 that the jet 15 no longer enters the bore 3, but impinges exclusively on the top surface.
  • angles ⁇ and / or ⁇ > 5 ° are sufficient to achieve the desired peeling effect or splitting action of the liquid jet 15.
  • Conventional erosion processes using a high-pressure water jet direct the water jet diffusely onto the layer to be removed, here the overspray 13, and destroy the overspray 13 by means of a very high water pressure. This procedure is much more energy-intensive and requires higher construction costs because of the higher operating pressure ,
  • the inventive method has the further advantage that the removal rate is significantly increased.
  • FIG. 1 only one nozzle 17 and one spray jet 15 are shown. It is of course also possible, several distributed over the circumference and in FIG. 1 not shown nozzles 17, which, although offset over the circumference at the same angle ⁇ directed to the top surface 7, provide. Such a group of rectified nozzles 17 will be referred to as a nozzle register hereinafter.
  • FIGS. 2 and 3 each representing different embodiments of the lower end of a piston raceway 3 and the adjacent areas with overspray 13.
  • the FIGS. 2 and 3 are intended to illustrate that a wide variety of geometries and contours on the end of the cylinder barrel 3 adjacent areas surfaces of the workpiece 1 are possible and consequently the nature, size and nature of the overspray can be correspondingly different.
  • FIG. 4 a second embodiment of a spray lance 9 is shown.
  • the nozzle 17 is directed upward such that the spray jet 15 impinges on the surface of the workpiece at a second angle ⁇ of about 45 ° in the region where overspray is present on the workpiece 1.
  • the second angle ⁇ between the beam 5 and the workpiece surface is larger than in the embodiment according to FIG. 1 , which is due to the contour of the workpiece 1.
  • the overspray 13 mounted in a recess of the workpiece 1, so that beam 15 only reaches all of the overspray 13 covered areas of the workpiece 1, if he is a little steeper on the Workpiece surface is directed.
  • the point at which the jet 15 begins to remove the overspray 13 is farthest from the piston barrel 3, the thickness of the overspray 13 is minimal and the adhesion of the overspray 13 is the worst. Therefore, it is also possible with these slightly larger angle between the beam 15 and the workpiece surface according to the invention to peel off the overspray. In this case, relatively large pieces of overspray 13 burst from the surface of the workpiece 1, so that overall sets a very efficient and effective removal of overspray 13 despite the angle of about 45 ° between the beam 15 and the workpiece surface.
  • FIG. 5 is exemplified and greatly enlarged such a chipped particle of overspray 13 is shown.
  • particles with a length of about 10 mm and a width of about 5 mm particles flake off and thus the overspray 13 is not shattered, but like the FIGS. 1 and 4 illustrate, is peeled off.
  • the mechanism of action according to the invention is based on the fact that the jet 15 penetrates between overspray 13 and the substrate or the workpiece surface 1 in the manner of a "splitting wedge".
  • FIG. 6 Such an embodiment of such a lance 9 is shown.
  • This lance 9 protrudes through the entire piston raceway 3 therethrough.
  • the first register of nozzles 17.1 is directed to the overspray on the top surface 7, while a second register of nozzles 17.2 is directed from below to the overspray in the region below the piston barrel 3.
  • This lance 9 is to a certain extent the combination of in the FIGS. 1 and 4 illustrated lances. This makes it possible to remove the overspray 13 above and below the piston barrel 3 at the same time and with high efficiency, which reduces the cycle times and makes the inventive method even more economical.
  • nozzles 17 pivotably in the lance 9, so that they can be directed to the surface of the workpiece 1 according to the current position of the lance 9, so that the beam with the smallest possible angle on the surface of the workpiece 1 hits.
  • the best possible peeling effect or splitting effect between the overspray 13 and the workpiece is achieved, so that the overspray 13 can be removed quickly and safely with low blasting agent and energy expenditure.
  • a local pressure adjustment to the course of the topography is possible through an automated cycle. This is then required if the course of the workpiece surface to be blasted is unfavorable.
  • Beam parameters in the exemplary embodiment Print: 28 MPa Flow rate / nozzle: 5.6 l / min Number of nozzles: 6 Nozzle diameter: 0.9 mm Total current: 34 l / min Nozzle distance: ⁇ 15 mm Material of the nozzles: sapphire

Description

Die Eigenschaften von Funktionsflächen, wie zum Beispiel die Kolbenlaufbahnen in den Zylindern von Verbrennungsmotoren, können durch Beschichten, insbesondere durch thermisches Beschichten eingestellt und verbessert werden. Beim thermischen Beschichten wird der als Draht oder Pulver zugeführte Spritzwerkstoff im Prozess erschmolzen, so dass einzelne Partikel (Droplets) im flüssigen oder teigigen Zustand im Spritzstrahl gegen das Substrat bewegt werden. Aufgrund der unterschiedlichen Partikelgröße entsteht ein Kernstrahl mit vollständig erschmolzenen Partikeln und beidseitigen Randstrahlen mit nur teilweise erschmolzenen Partikeln, die in einem bestimmten Öffnungswinkel zum Kernstrahl verlaufen. Die eigentliche Beschichtung erfolgt mit dem Kernstrahl.The properties of functional surfaces, such as the piston races in the cylinders of internal combustion engines, can be adjusted and improved by coating, in particular by thermal coating. During thermal coating, the spray material supplied as wire or powder is melted in the process, so that individual particles (droplets) in the liquid or doughy state are moved in the spray jet against the substrate. Due to the different particle size, a core jet with completely molten particles and two-sided marginal rays with only partially melted particles, which extend at a certain opening angle to the core beam. The actual coating takes place with the core jet.

An den Rändern der zu beschichtenden Funktionsfläche, z. B. an der oberen und unteren Bohrungskante einer Zylinderbohrung, verlassen die Randstrahlen die Funktionsfläche und setzen sich außerhalb der Funktionsfläche auf dem Werkstück nieder und bilden dort unerwünschte Anhaftungen. Diese Anhaftungen werden nachfolgend als Overspray bezeichnet. Der Overspray ist unerwünscht, da er sich während des Betriebs des Motors von dem Werkstück lösen kann. Die dadurch unkontrolliert entstehenden Partikel gelangen in den Ölkreislauf und verursachen einen erhöhten Verschleiß oder sogar den Totalausfall des Verbrennungsmotors.At the edges of the functional surface to be coated, z. B. at the upper and lower bore edge of a cylinder bore, the edge rays leave the functional surface and sit down outside the functional area on the workpiece and form there undesirable adhesions. These adhesions are referred to as overspray below. The overspray is undesirable because it can become detached from the workpiece during operation of the motor. The resulting uncontrolled particles enter the oil circuit and cause increased wear or even the total failure of the engine.

Zur Vermeidung von Overspray werden die Werkstücke oft maskiert, sodass die anliegende Fläche nicht beschichtet werden kann. Die dazu erforderlichen Masken müssen von Hand an den vorgesehenen Stellen des Werkstücks befestigt werden. Daher ist das Maskieren sehr aufwändig und bisher nicht automatisierbar. Das thermische Spritzen von Zylinderbohrungen konnte sich daher nur in der Kleinserienfertigung durchsetzen.To avoid overspray, the workpieces are often masked so that the adjacent surface can not be coated. The required masks must be done by hand be attached to the intended locations of the workpiece. Therefore, the masking is very complex and so far not automatable. The thermal spraying of cylinder bores could therefore prevail only in the small series production.

Es besteht auch die Möglichkeit, den Overspray durch spanende Verfahren mit geometrisch bestimmter oder unbestimmter Schneide abzutragen. Diese Methode ist aufgrund der im Kurbelgehäuse unterhalb der Zylinderbohrung vorhandenen Geometrien schwierig zu automatisieren.It is also possible to remove the overspray by cutting processes with geometrically determined or undefined cutting edge. This method is difficult to automate due to the existing in the crankcase below the cylinder bore geometries.

Aus der US 5, 167, 721 ist es bekannt bei der Überholung oder Reparatur eines beschichteten Bauteils einer Gasturbine die Beschichtung großflächig mittels Wasserstrahl zu entfernen.From the US 5, 167, 721 It is known in the overhaul or repair of a coated component of a gas turbine to remove the coating over a large area by means of water jet.

Alternativ ist es auch bekannt, Schichten von einem Substrat durch Hochdruckwasserstrahlen zu entfernen (siehe Lugscheider, E.: Handbuch der thermischen Spritztechnik. Fachbuchreihe Schweißtechnik Band 139, Verlag für Schweißen und verwandte Verfahren DVS - Verlag GmbH, Düsseldorf. 2002. ISBN 3-87155-186-4, Seite 116 ff ). Dabei wird ein Wasserstrahl mit hohem Druck mehr oder weniger senkrecht oder diffus auf die abzutragende Schicht gerichtet. Durch die kinetische Energie des Wasserstrahls wird die Zerstörung der anhaftenden Schicht und in Folge dessen das Abtragen der Schicht bewirkt. Der Wasserstrahl ist mit hoher Präzision positionierbar und erlaubt ein gezieltes lokales Abtragen in den gewünschten Bereichen. Der Nachteil der bekannten hydromechanischen Abtragverfahren besteht in den hohen Betriebsdrücken der Wasserstrahlsysteme, welche in der Literatur mit 150 MPa bis 400 MPa angegeben werden. Damit kann die Oberfläche des Werkstücks im Bereich der mit Overspray überzogenen Randzone unzulässig verändert oder sogar geschädigt werden. Um zu verhindern, dass die Funktionsschicht durch den Hochdruckwasserstrahl geschädigt wird, muss in manchen Fällen die Funktionsschicht durch Masken vor dem Hochdruckwasserstrahl geschützt werden, mit den oben erwähnten Nachteilen. Außerdem verursacht das Hochdruckwasserstrahlen einen hohen Energiebedarf für den Betrieb der Anlage und erfordert eine sehr teure Anlagentechnik.Alternatively, it is also known to remove layers from a substrate by high pressure water jets (see Lugscheider, E .: Handbook of Thermal Spray Technique. Fachbuchreihe Schweißtechnik volume 139, publishing house for welding and allied procedures DVS - publishing house GmbH, Duesseldorf. 2002. ISBN 3-87155-186-4, page 116 ff ). In this case, a high-pressure water jet is directed more or less vertically or diffusely onto the layer to be ablated. The kinetic energy of the water jet causes the destruction of the adherent layer and, as a result, the removal of the layer. The water jet can be positioned with high precision and allows a targeted local removal in the desired areas. The disadvantage of the known hydromechanical removal methods is the high operating pressures of the water jet systems, which are reported in the literature as 150 MPa to 400 MPa. As a result, the surface of the workpiece in the region of the overspray-coated edge zone can be changed inadmissibly or even damaged. In order to prevent the functional layer from being damaged by the high-pressure water jet, in some cases the functional layer has to be protected by masks from the high-pressure water jet, with the above-mentioned disadvantages. In addition, the high pressure water jetting causes a high energy demand for the Operation of the system and requires a very expensive equipment.

Die der Erfindung zugrunde liegende Aufgabe besteht darin ein Verfahren bereitzustellen, welches das prozesssichere Entfernen von Overspray an den der Bohrung benachbarten Flächen erlaubt und dabei die aus dem Stand der Technik bekannten Nachteile weitestgehend überwindet. Insbesondere soll das Verfahren für Großserien geeignet sein, was eine vollständige Automatisierbarkeit bei gleichzeitig geringen Energiekosten und hoher Prozesssicherheit erfordert.The object underlying the invention is to provide a method which allows the process-reliable removal of overspray on the surfaces adjacent to the bore, thereby largely overcoming the disadvantages known from the prior art. In particular, the method should be suitable for large series, which requires complete automation with simultaneously low energy costs and high process reliability.

Diese Aufgabe wird erfindungsgemäß gelöst durch ein Verfahren zum Abtragen des Overspray einer auf ein Werkstück aufgespritzten Schicht, bei dem mindestens ein Flüssigkeitsstrahl einer Strahllanze auf die mit Overspray versehenen Bereiche des Werkstücks gerichtet wird, wobei der mindestens eine Flüssigkeitsstrahl unter einem Winkel kleiner 90°, bevorzugt kleiner 60° und besonders bevorzugt kleiner 30° und größer 5° ist.This object is achieved by a method for removing the overspray of a sprayed onto a workpiece layer in which at least one liquid jet of a jet lance is directed to the overspray provided areas of the workpiece, wherein the at least one liquid jet at an angle less than 90 °, preferably less than 60 ° and more preferably less than 30 ° and greater than 5 °.

Das erfindungsgemäße Verfahren macht sich die Erkenntnis zunutze, dass die an die eigentliche Funktionsfläche anschließenden Oberflächen des Werkstücks nicht besonders für das Aufbringen einer Schicht vorbereitet wurde, so dass die Droplets beziehungsweise die Partikel weniger intensiv auf dem Werkstück haften, als dies auf der eigentlichen Funktionsfläche der Fall ist. Ein Grund hierfür ist darin zusehen, dass im Bereich der Funktionsflächen die Beschichtung, wie bereits erwähnt, durch den Kernstrahl mit vollständig aufgeschmolzenen Droplets erfolgt. Ein weiterer Effekt, der die Haftbedingungen zwischen Overspray und der Oberfläche des Substrats verschlechtert, ist darin zu sehen, dass die Droplets einen weiteren Weg zurücklegen müssen bis sie auf den zur Funktionsfläche benachbarten Bereich des Werkstücks auftreffen. Dadurch kühlen die Droplets stärker ab, was deren Haftung auf der Werkstückoberfläche weiter verringert. Diese Erkenntnis macht sich das erfindungsgemäße Verfahren zunutze, indem es den Flüssigkeitsstrahl unter einem möglichst flachen Winkel, der so klein wie möglich sein sollte, um eine gute Schälwirkung zu erzielen, auf die Oberfläche des Werkstücks richtet.The method according to the invention makes use of the knowledge that the surfaces of the workpiece adjoining the actual functional surface were not specially prepared for the application of a layer, so that the droplets or the particles adhere to the workpiece less intensively than on the actual functional surface of the workpiece Case is. One reason for this is that in the area of the functional surfaces, the coating, as already mentioned, takes place through the core jet with completely melted droplets. Another effect that degrades the adhesion conditions between overspray and the surface of the substrate is to be seen in the fact that the droplets must cover a further path until they impinge on the region of the workpiece adjacent to the functional surface. As a result, the droplets cool more strongly, which further reduces their adhesion to the workpiece surface. This realization makes the invention Benefit method by the liquid jet at the lowest possible angle, which should be as small as possible to achieve a good peeling effect, directed to the surface of the workpiece.

In der Praxis haben sich Winkel von weniger als 30°, bevorzugt weniger als 20° und besonders bevorzugt weniger als 10° als geeignet erwiesen. Idealerweise wirkt der Flüssigkeitsstrahl mehr oder weniger parallel zu der Kontaktfläche zwischen Substrat und Beschichtung.In practice, angles of less than 30 °, preferably less than 20 ° and more preferably less than 10 °, have proven suitable. Ideally, the liquid jet acts more or less parallel to the contact surface between substrate and coating.

Die erfindungsgemäße Schälwirkung wird unterstützt, wenn der Flüssigkeitsstrahl gewissermaßen von außen, d. h. von der unbeschichteten Werkstückoberfläche in Richtung der mit Overspray behafteten Bereiche der Werkstückoberfläche geführt wird. Dadurch wird die Ablösung des Oversprays durch "Schälen" anstelle des "Zertrümmerns" untertsützt.The peeling effect according to the invention is assisted if the liquid jet is to some extent externally, i. H. is guided by the uncoated workpiece surface in the direction of the overspray-prone areas of the workpiece surface. As a result, the overspray is replaced by "peeling" instead of "smashing".

Dadurch wirkt der Flüssigkeitsstrahl wie ein hydrodynamischer Keil, der sich in der Trennebene zwischen Substrat beziehungsweise die Oberfläche des Werkstücks und aufgespritzter Schicht(Overspray) und schiebt. Dadurch wird das Ablösen des Oversprays deutlich vereinfacht. Außerdem kann wegen der erfindungsgemäßen Ausrichtung des Flüssigkeitsstrahls der Arbeitsdruck des Flüssigkeitsstrahls deutlich reduziert werden, was sich positiv auf den Energiebedarf und somit auch auf die Betriebskosten auswirkt.As a result, the liquid jet acts like a hydrodynamic wedge, which slides in the parting plane between the substrate or the surface of the workpiece and the sprayed-on layer (overspray). This significantly simplifies the removal of the overspray. In addition, due to the inventive alignment of the liquid jet, the working pressure of the liquid jet can be significantly reduced, which has a positive effect on the energy requirements and thus also on the operating costs.

In weiterer vorteilhafter Ausgestaltung des erfindungsgemäßen Verfahrens ist vorgesehen, dass die Strahllanze und/oder die Austrittsrichtung des mindestens einen Flüssigkeitsstrahls aus der Strahllanze in Abhängigkeit von der Ausrichtung der Oberfläche des Werkstücks in den mit Overspray versehenen Bereichen gesteuert wird. Dadurch ist es möglich, auch bei konkav oder konvex gekrümmten Oberflächen des Substrats immer einen optimalen Winkel zwischen dem Flüssigkeitsstrahl und der Oberfläche an dem Punkt, wo der Flüssigkeitsstrahl auf die Oberfläche auftritt, zu erreichen. Infolgedessen werden unabhängig von der Geometrie in der Oberflächenkontur des Werkstücks immer optimale Abtragbedingungen erzielt, so dass auch bei kompliziert geformten Geometrien das erfindungsgemäße Verfahren wirkungsvoll und effizient einsetzbar ist.In a further advantageous embodiment of the method according to the invention it is provided that the jet lance and / or the outlet direction of the at least one liquid jet from the jet lance is controlled in dependence on the orientation of the surface of the workpiece in the areas provided with overspray. This makes it possible, even with concave or convex curved surfaces of the substrate always to achieve an optimum angle between the liquid jet and the surface at the point where the liquid jet occurs on the surface. As a result, will regardless of the geometry in the surface contour of the workpiece always optimal removal conditions achieved, so that even with complicated shaped geometries method of the invention can be used effectively and efficiently.

In weiterer vorteilhafter Ausgestaltung des erfindungsgemäßen Verfahrens ist vorgesehen, dass die Strahllanze eine Rotationsbewegung ausführt. Dadurch werden auf einfachste Weise alle Bereiche rund um die Strahllanze gleichmäßig von dem Sprühstrahl erfasst und somit der Overspray vollständig entfernt.In a further advantageous embodiment of the method according to the invention it is provided that the jet lance executes a rotational movement. As a result, in the simplest way all areas around the jet lance are uniformly detected by the spray jet and thus the overspray is completely removed.

Um möglichst alle und zwar auch komplexe Oberflächenkonturen von Werkstücken wirkungsvoll vom Overspray befreien zu können, ist vorgesehen, dass die Richtung mindestens eines Flüssigkeitsstrahls der Strahllanze mit einer von der Drehachse der Strahllanze und einem Radiusstrahl aufgespannten Ebene, die sogenannte Z-R-Ebene, einen ersten Winkel α einschließt, und dass der erste Winkel α größer 5° und kleiner 85° ist.In order to be able to effectively free as much as possible from all over, even complex surface contours of workpieces, it is provided that the direction of at least one liquid jet of the jet lance with a plane defined by the axis of rotation of the jet lance and a radius beam plane, the so-called ZR plane, a first angle α includes, and that the first angle α is greater than 5 ° and less than 85 °.

In weiterer Ausgestaltung des erfindungsgemäßen Verfahrens ist vorgesehen, dass die Richtung mindestens eines Flüssigkeitsstrahls mit einer Ebene (X-Y-Ebene), die lotrecht zu einer Z-Achse der Strahllanze angeordnet ist, einen zweiten Winkel β einschließt, und dass der zweite Winkel größer 5° und kleiner 85° ist. Durch diese Winkelbereiche, die gewissermaßen in einem fest mit der Strahllanze verbundenen Zylinderkoordinaten-System definiert sind, lassen sich selbst bei komplizierten Konturen der mit Overspray versehenen Oberflächen von Werkstücken die optimalen erfindungsgemäßen Abtragbedingungen für das Overspray erreichen.In a further embodiment of the method according to the invention it is provided that the direction of at least one liquid jet with a plane (XY plane), which is arranged perpendicular to a Z-axis of the jet lance, a second angle β includes, and that the second angle greater than 5 ° and less than 85 °. By means of these angular ranges, which are effectively defined in a cylindrical coordinate system fixedly connected to the jet lance, it is possible to achieve the optimum removal conditions for the overspray according to the invention, even with complicated contours of the surfaces provided with overspray.

Damit das erfindungsgemäße Verfahren auch bei komplexen Geometrien unverändert wirksam ist, ist erfindungsgemäß vorgesehen, dass mindestens eine Düse der Strahllanze verschwenkbar ist und zwar so, dass der erste Winkel α und der zweite Winkel β in jeweils in Bereichen zwischen 5° und 85° einstellbar sind. Dadurch ist es möglich, dass der Sprühstrahl der Strahllanze immer unter annähernd gleichen Winkeln auf die Oberfläche des Werkstücks auftrifft.In order for the method according to the invention to remain unchanged even in the case of complex geometries, it is provided according to the invention that at least one nozzle of the jet lance is pivotable in such a way that the first angle α and the second angle β in each case in ranges between 5 ° and 85 ° are adjustable. This makes it possible that the spray jet of the jet lance always impinges on the surface of the workpiece at approximately equal angles.

Es hat sich weiter als vorteilhaft erwiesen, dass als Flüssigkeit für das Abtragen ein Kühlschmiermittel, vorzugsweise ein mit Wasser mischbares Kühlschmiermittel eingesetzt wird. Das Konzentrat dieser Mischung ist so ausgewählt, dass eine mineralölhaltige Emulsion oder eine synthetische mineralölfreie Lösung als Fluid zur Verfügung steht. Dieses Kühlschmiermittel hat den Vorteil, dass es das zuvor beim thermischen Beschichten erwärmte Werkstück und insbesondere dessen Funktionsoberfläche (Zylinderbohrung) abkühlt. Dadurch kann das Werkstück besser und rascher in den nachgelagerten Bearbeitungsprozessen bearbeitet werden.It has also proved to be advantageous that a cooling lubricant, preferably a water-miscible cooling lubricant, is used as the liquid for the removal. The concentrate of this mixture is selected so that a mineral oil-containing emulsion or a synthetic mineral oil-free solution is available as a fluid. This cooling lubricant has the advantage that it cools the previously heated during thermal coating workpiece and in particular its functional surface (cylinder bore). This allows the workpiece to be processed better and faster in the downstream machining processes.

Dieses Kühlschmiermittel hat außerdem den Vorteil, dass es nicht korrosiv ist und somit keine Korrosion an den mit dem erfindungsgemäßen Verfahren behandelten Werkstücken auftritt.This cooling lubricant also has the advantage that it is not corrosive and thus no corrosion occurs on the treated with the inventive process workpieces.

Des Weiteren werden solche Kühlschmiermittel auch in den nachgelagerten Prozessen, wie zum Beispiel Honen oder Anfasen der Zylinderbohrung eingesetzt. Dadurch ist dieses Kühlschmiermittel erstens schon verfügbar und es besteht keine Notwendigkeit, die Flüssigkeiten zum Abtragen des Oversprays von den Kühlschmiermitteln in den nachgelagerten Prozessen zu trennen. Dadurch ergibt sich einer erhebliche Vereinfachung bei der Prozessführung. Außerdem wird nur eine Wiederaufbereitungs- und Pumpeinrichtung für die gesamte Fertigungslinie benötigt.Furthermore, such cooling lubricants are also used in the downstream processes, such as honing or chamfering the cylinder bore. As a result, this cooling lubricant is firstly already available and there is no need to separate the liquids for removing the overspray from the cooling lubricants in the downstream processes. This results in a considerable simplification in the process management. In addition, only one reconditioning and pumping device is needed for the entire production line.

Es hat sich als ausreichend erwiesen, wenn das Kühlschmiermittel mit einem Druck in einem Bereich zwischen 15 MPa und 60 MPa, bevorzugt in einem Bereich zwischen 20 MPa und 50 MPa, und besonders bevorzugt in einem Bereich zwischen 25 MPa und 40 MPa, der oder den Düsen, welche den Flüssigkeitsstrahl bilden, zugeführt wird. Diese Druckbereiche sind deutlich niedriger als die im Stand der Technik genannten Drücke für das herkömmliche HochdruckWasserstrahlen. Aus den niedrigeren Betriebsdrücken resultieren erhebliche Vorteile hinsichtlich des Energiebedarfs, aber auch die konstruktive Auslegung der erfindungsgemäßen Strahleinrichtung kann deutlich vereinfacht werden. Außerdem ist die Unfallgefahr aufgrund der niedrigeren Betriebsdrücke und damit verbunden der geringeren kinetischen Energie des Flüssigkeitsstrahls geringer.It has proved to be sufficient if the cooling lubricant with a pressure in a range between 15 MPa and 60 MPa, preferably in a range between 20 MPa and 50 MPa, and particularly preferably in a range between 25 MPa and 40 MPa, the or Nozzles, which the Liquid jet form, is supplied. These pressure ranges are significantly lower than the pressures referred to in the prior art for conventional high pressure water jetting. From the lower operating pressures result in considerable advantages in terms of energy requirements, but also the structural design of the jet device according to the invention can be significantly simplified. In addition, the risk of accidents due to the lower operating pressures and the associated lower kinetic energy of the liquid jet is lower.

Um die Wirksamkeit des erfindungsgemäßen Verfahrens weiter zu optimieren und auch bei sehr komplexen Geometrien konstant hoch zu halten, ist weiter vorgesehen, dass der Druck mit dem das Kühlschmiermitteln den Düsen der Strahllanze zugeführt wird, in Abhängigkeit der rotatorischen und/oder translatorischen Position der Düsen gesteuert werden kann. Die Steuerung des Drucks ist eine Möglichkeit, Stellen an denen der Overspray besonders hartnäckig anhaftet, gezielt mit einer höheren kinetischer Energie des Flüssigkeitsstrahls zu beaufschlagen, um auf diese Weise ein optimales Abtragergebnis zu erzielen. Umgekehrt kann der Druck auch abgesenkt werden, wenn der Overspray in bestimmten Bereich sehr leicht entfernbar ist.In order to further optimize the effectiveness of the method according to the invention and to keep it consistently high even with very complex geometries, it is further provided that the pressure with which the cooling lubricant is supplied to the nozzles of the jet lance is controlled as a function of the rotational and / or translational position of the nozzles can be. The control of the pressure is a way to specifically apply pressure to places where the overspray adheres particularly vigorously to a higher kinetic energy of the liquid jet, in order to achieve an optimal removal result in this way. Conversely, the pressure can also be lowered if the overspray is very easily removable in a certain area.

In ähnlicher Weise ist es auch möglich, auch den Volumenstrom des durch die Düsen der Strahllanze geförderten Kühlschmiermittels in Abhängigkeit der rotatorischen und/oder translatorischen Position der Düsen zu steuern.Similarly, it is also possible to control the volume flow of the conveyed through the nozzles of the jet lance coolant according to the rotational and / or translational position of the nozzles.

Das erfindungsgemäße Verfahren ist Teil einer Fertigungskette und wird natürlich erst dann eingesetzt, wenn eine oder mehrere Funktionsflächen zum Beispiel durch thermisches Spritzen mit einer Beschichtung versehen wurde. Dann kann das erfindungsgemäße Verfahren direkt anschließend eingesetzt werden, um den Overspray zu entfernen. In diesem Fall bewirkt der Flüssigkeitsstrahl auch eine Abkühlung des Werkstücks, besonders beider Verwendung von wässrigen Flüssigkeiten. Dies ist ein zusätzlicher positiver Effekt des erfindungsgemäßen Verfahrens, da nach dem thermischen Beschichten die Werkstücktemperatur über 100 °C betragen kann und eine anschließende Honoperation aus Gründen der Maßhaltigkeit eine Werkstücktemperatur von max. 25 °C erfordert. Anschließend kann die zuvor beschichtete Funktionsfläche gehont werden und, falls erforderlich, die Kanten der gehonten Funktionsfläche mit einer Fase versehen werden.The method according to the invention is part of a production chain and of course is only used when one or more functional surfaces has been provided with a coating, for example by thermal spraying. Then, the method according to the invention can be used directly afterwards to remove the overspray. In this case, the liquid jet also causes a cooling of the workpiece, especially when using aqueous liquids. This is an additional positive effect of the method according to the invention, since after the thermal coating, the workpiece temperature can be above 100 ° C and a subsequent honing operation for reasons of dimensional accuracy a workpiece temperature of max. 25 ° C required. Then the previously coated functional surface can be honed and, if necessary, beveled with the edges of the honed functional surface.

Alternativ ist es auch möglich, dass zunächst die beschichtete Funktionsfläche aktiv oder passiv zum Beispiel mit einem Kühlmittel auf Wasserbasis (Kühlschmiermittel) abgekühlt und dann gehont wird. Im Anschluss an das Honen wird der Overspray mit dem erfindungsgemäßen Verfahren entfernt wird und schließlich werden die Kanten der gehonten Funktionsfläche mit einer Fase versehen.Alternatively, it is also possible for the coated functional surface to be actively or passively cooled, for example with a water-based coolant (cooling lubricant), and then honed. Following honing, the overspray is removed by the method according to the invention and finally the edges of the honed functional surface are provided with a chamfer.

Die der Erfindung zugrundeliegende Aufgabe wird auch gelöst durch eine Strahllanze zur Durchführung eines der vorhergehenden Verfahren zur vollständigen oder teilweisen Entfernung von Overspray, wobei die Strahllanze eine Aufnahme, mindestens einen Kühlschmiermittelanschluss und mindestens eine Düse umfasst, wobei die mindestens eine Düse der Strahllanze mit einer von der Drehachse der Strahllanze und einem Radiusstrahl aufgespannten Ebene (Z-R-Ebene), einen ersten Winkel α einschließt, und wobei der erste Winkel α größer 5° und kleiner 85° ist. In anderen Worten: Ein erster Winkel α = 0° entspricht einem Radiusstrahl, während ein erster Winkel α = 90° einer Tangente entspricht.The object underlying the invention is also achieved by a jet lance for performing one of the preceding methods for complete or partial removal of overspray, wherein the jet lance comprises a receptacle, at least one cooling lubricant connection and at least one nozzle, wherein the at least one nozzle of the jet lance with one of the axis of rotation of the jet lance and a radius plane spanned plane (ZR plane), a first angle α includes, and wherein the first angle α is greater than 5 ° and less than 85 °. In other words, a first angle α = 0 ° corresponds to a radius beam, while a first angle α = 90 ° corresponds to a tangent.

In entsprechender Weise kann die mindestens eine Düse der Strahllanze mit einer Ebene (X-Y-Ebene), die lotrecht zu der Drehachse (Z-Achse) angeordnet ist, einen zweiten Winkel β einschließen, wobei der zweite Winkel β erfindungsgemäß > 5° und < 85 ° ist. Eine solche Strahllanze ermöglicht es, den Winkel zwischen dem Flüssigkeitsstrahl und der Oberfläche des Werkstücks dem erfindungsgemäßen Verfahren entsprechend einzustellen.In a corresponding manner, the at least one nozzle of the jet lance with a plane (XY plane), which is arranged perpendicular to the rotation axis (Z axis), a second angle β include, wherein the second angle β according to the invention> 5 ° and <85 ° is. Such a jet lance allows the angle between the liquid jet and the surface of the Set workpiece according to the method according to the invention.

Wenn die Kontur des Werkstücks komplex ist, kann es auch vorteilhaft sein, dass die mindestens eine Düse der Strahllanze verschwenkbar ist, so dass der erste Winkel α und/oder der zweite Winkel β einstellbar ist. Die Schwenkeinrichtung der mindestens einen Düse kann von einer numerischen Steuerung angesteuert werden, so dass während der Bearbeitung der Flüssigkeitsstrahl immer so ausgerichtet werden kann, dass er möglichst unter einem flachen Winkel auf die Werkstückoberfläche auftritt.If the contour of the workpiece is complex, it may also be advantageous that the at least one nozzle of the jet lance is pivotable, so that the first angle α and / or the second angle β is adjustable. The pivoting device of the at least one nozzle can be controlled by a numerical control, so that during the processing of the liquid jet can always be aligned so that it occurs as possible at a shallow angle to the workpiece surface.

Es ist selbstverständlich auch möglich und vorteilhaft, wenn mehrere Düsen an einer Strahllanze vorgesehen sind und diese Düsen in verschiedenen ersten Winkeln α oder zweiten Winkeln β ausgerichtet sind. Dann ist es möglich, den Flüssigkeitsstrahl auch bei komplizierten Konturen des Werkstücks immer unter einem günstigen Winkel auf jeden Bereich des Werkstücks zu richten, selbst wenn die Düsen feststehend, also nicht schwenkbar, an der Strahllanze angeordnet sind. Dadurch ergibt sich trotz der vereinfachten konstruktiven Ausgestaltung der Strahllanze ein optimales Ergebnis.It is of course also possible and advantageous if a plurality of nozzles are provided on a jet lance and these nozzles are aligned at different first angles α or second angles β. Then it is possible, even with complicated contours of the workpiece to direct the liquid jet at a favorable angle to each area of the workpiece, even if the nozzles are fixed, so not pivotally mounted on the jet lance. This results in spite of the simplified structural design of the jet lance an optimal result.

Um den Energie- und Kühlschmiermittelbedarf der erfindungsgemäßen Strahllanze zu minimieren, ist weiter vorgesehen, dass die Düsen einzeln zuschaltbar und abschaltbar sind. Diese Schaltvorgänge können auch während des Betriebs der Strahllanze erfolgen, so dass auch dadurch eine im Hinblick auf den Energie- und Flüssigkeitsbedarf optimierte Strahlführung trotz feststehender Düsen möglich ist.In order to minimize the energy and cooling lubricant requirement of the jet lance according to the invention, it is further provided that the nozzles can be individually switched on and switched off. These switching operations can also take place during the operation of the jet lance, so that even in this way an optimized beam guidance with regard to the energy and fluid requirements is possible despite fixed nozzles.

Um den Overspray an den benachbarten Flächen beider Enden einer Kolbenlaufbahn eines Verbrennungsmotors gleichzeitig abtragen zu können, ist in weiterer vorteilhafter Ausgestaltung vorgesehen, dass die Düsen in Längsrichtung der Z-Achse der Strahllanze zueinander beabstandet angeordnet sind, so dass an beiden Enden der beschichteten Funktionsflächen der Overspray gleichzeitig entfernt werden kann. Dadurch ergibt sich eine Verringerung der Taktzeiten, was insbesondere bei der Serienfertigung von Verbrennungskraftmaschinen ein wesentlicher Vorteil ist. Auch auf eine Markierung kann vollständig verzichtet werden. Damit ist erstmalig eine automatisierte Anwendung in der Großserienfertigung möglich.In order to be able to remove the overspray at the adjacent surfaces of both ends of a piston raceway of an internal combustion engine at the same time, it is provided in a further advantageous embodiment that the nozzles in the longitudinal direction of Z-axis of the jet lance are arranged spaced from each other, so that at both ends of the coated functional surfaces of the overspray can be removed simultaneously. This results in a reduction of the cycle times, which is a significant advantage, especially in mass production of internal combustion engines. Even a mark can be completely dispensed with. For the first time an automated application in mass production is possible.

Weitere Vorteile und vorteilhafte Ausgestaltungen der Erfindung werden in der nachfolgenden Zeichnung, deren Beschreibung und deren Patentansprüchen beschrieben. Alle in der Zeichnung, deren Beschreibung und den Patentansprüchen offenbarten Merkmale können sowohl einzeln als auch in beliebiger Kombination miteinander erfindungswesentlich sein.Further advantages and advantageous embodiments of the invention are described in the following drawings, their description and their claims. All of the features disclosed in the drawing, the description and the claims can be essential to the invention both individually and in any combination with one another.

Zeichnungdrawing

Es zeigen

  • Figur 1 Eine beschichtete Kolbenlaufbahn im Längsschnitt mit einem ersten Ausführungsbeispiel einer erfindungsgemäßen Strahllanze,
  • Figuren 2 und 3 Details der Werkstückoberfläche, Beispiele komplexer Geometrien, komplexer Konturen des Werkstücks in unmittelbarer Nähe der beschichteten Zylinderbohrung,
  • Figur 4 eine stark vergrößerte schematische Darstellung des erfindungsgemäßen Abtragvorgangs,
  • Figur 5 ein mit dem erfindungsgemäßen Verfahren abgetragener Partikel des Oversprays und
  • Figur 6 ein Ausführungsbeispiel einer erfindungsgemäßen Strahllanze mit der an beiden Enden der Funktionsfläche (Kolbenlaufbahn) gleichzeitig der Overspray entfernt werden kann.
Show it
  • FIG. 1 A coated piston barrel in longitudinal section with a first embodiment of a jet lance according to the invention,
  • FIGS. 2 and 3 Details of the workpiece surface, examples of complex geometries, complex contours of the workpiece in the immediate vicinity of the coated cylinder bore,
  • FIG. 4 a greatly enlarged schematic representation of the removal process according to the invention,
  • FIG. 5 a abraded with the inventive method particles of the overspray and
  • FIG. 6 an embodiment of a jet lance according to the invention with the at both ends of the functional surface (piston raceway) can be removed simultaneously overspray.

Beschreibung der AusführungsbeispieleDescription of the embodiments

In Figur 1 ist ein Zylinderblock 1, der nachfolgend auch als Werkstück oder Substrat bezeichnet wird, mit einer Kolbenlaufbahn 3 im Längsschnitt dargestellt. Auf der Kolbenlaufbahn 3 ist eine Beschichtung 5 durch thermisches Spritzen aufgebracht. Diese Beschichtung bildet nach dem Honen eine Funktionsoberfläche, die hinsichtlich Verschleiß und Ölverbrauch des Verbrennungsmotors optimiert ist.In FIG. 1 is a cylinder block 1, which is also referred to below as a workpiece or substrate, shown with a piston barrel 3 in longitudinal section. On the piston barrel 3, a coating 5 is applied by thermal spraying. After honing, this coating forms a functional surface which is optimized with regard to wear and oil consumption of the internal combustion engine.

Die Kolbenlaufbahn 3 endet in Figur 1 oben an der sogenannten Deckfläche 7, auf welche später die Zylinderkopfdichtung und der Zylinderkopf aufgesetzt werden (nicht dargestellt).The piston raceway 3 ends in FIG. 1 at the top of the so-called top surface 7, on which later the cylinder head gasket and the cylinder head are placed (not shown).

Am unteren Ende der Kolbenlaufbahn 3 geht der Zylinderblock 1 in das Kurbelgehäuse über. Für die Erfindung von Bedeutung ist dabei, dass die Kontur des Zylinderblocks 1 unterhalb der Kolbenlaufbahn 3 Vorsprünge, Vertiefungen und andere "Unregelmäßigkeiten" aufweist.At the lower end of the piston raceway 3, the cylinder block 1 goes into the crankcase. It is of importance for the invention that the contour of the cylinder block 1 has projections, recesses and other "irregularities" underneath the piston raceway 3.

Am unteren Rand der Figur 1 sind drei Koordinatenachsen X, Y und Z eines kartesischen ortsfesten Koordinatensystems angegeben. Dabei ist die Z-Achse deckungsgleich mit der Längsachse der Kolbenlaufbahn 3 und einer Drehachse einer erfindungsgemäßen Strahllanze 9. Die Strahllanze 9 rotiert, wie durch einen Pfeil 11 angedeutet, um die Z-Achse.At the bottom of the FIG. 1 are given three coordinate axes X, Y and Z of a Cartesian stationary coordinate system. The Z-axis is congruent with the longitudinal axis of the piston raceway 3 and a rotation axis of a jet lance 9 according to the invention. The jet lance 9 rotates, as indicated by an arrow 11, about the Z-axis.

Orthogonal zu der Z-Achse ist daher an der Strahllanze noch eine R-Achse eingetragen, die in Richtung eines Radiusstrahls verläuft und fest mit der Strahllanze 9 verbunden ist. Sie macht also die Rotationsbewegung der Strahllanze 9 mit.Orthogonal to the Z-axis, therefore, an R-axis is entered at the jet lance, which extends in the direction of a radius jet and is fixedly connected to the jet lance 9. So it makes the rotational movement of the jet lance 9 with.

Das Beschichten der Kolbenlaufbahn 3 erfolgt dadurch, dass eine entsprechend ausgebildete Lanze (nicht dargestellt) in Richtung der Z-Achse in die Kolbenlaufbahn eingeführt wird und dabei die Schutzschicht 5 auf die Kolbenlaufbahn 3 aufspritzt. Dabei bewegt sich die Lanze einerseits in Richtung der Z-Achse und dreht sich gleichzeitig um die Z-Achse. Währenddessen tritt ein Strahl von aufgeschmolzenem Material, welches die Schicht 5 bildet, radial aus der Lanze aus und wird mit hoher kinetischer Energie auf die Kolbenlaufbahn 3 geblasen. Um eine optimale Haftung zu erzielen wird die Oberfläche der Kolbenlaufbahn 3 diesem Zweck entsprechend vorbereitet und entfettet. Dadurch ergibt sich eine sehr innige und unlösbare Verbindung zwischen der Schicht 5 und der eigentlichen Kolbenlaufbahn 3.The coating of the piston raceway 3 takes place in that a suitably formed lance (not shown) is introduced in the direction of the Z-axis in the piston raceway and thereby the protective layer 5 is sprayed onto the piston raceway 3. The lance moves on the one hand in the direction of the Z-axis and simultaneously rotates about the Z-axis. Meanwhile, a jet of melted occurs Material which forms the layer 5, radially from the lance and is blown with high kinetic energy to the piston raceway 3. In order to achieve optimum adhesion, the surface of the piston barrel 3 is prepared and degreased for this purpose. This results in a very intimate and permanent connection between the layer 5 and the actual piston barrel 3.

Da der Strahl, mit dem das aufgeschmolzene Material von der nicht dargestellten Lanze auf die Kolbenlaufbahn 3 gespritzt wird, sich vor dem Auftreffen auf der Kolbenlaufbahn 3 eine gewisse Aufweitung erfährt, ist der Strahl letztendlich kegelförmig ausgebildet. Dies bedeutet, dass immer dann, wenn sich die Lanze dem oberen Ende oder dem unteren Ende der Kolbenlaufbahn 3 nähert, ein geringer, aber nicht zu vernachlässigender Anteil des aufgeschmolzenen Materials nicht auf der Kolbenlaufbahn 3 auftrifft, sondern sich beispielsweise auf der Deckfläche 7 oder in den unteren Bereichen des Zylinderblocks 1 als sogenannter Overspray niederschlägt. In der Figur 1 ist dieser Overspray mit dem Bezugszeichen 13 versehen.Since the jet, with which the molten material is injected from the lance, not shown, to the piston raceway 3, experiences a certain expansion before hitting the piston raceway 3, the jet is ultimately cone-shaped. This means that whenever the lance approaches the upper end or the lower end of the piston barrel 3, a small, but not negligible proportion of the molten material does not impinge on the piston barrel 3, but for example on the top surface 7 or in the lower portions of the cylinder block 1 as so-called overspray reflected. In the FIG. 1 This overspray is provided with the reference numeral 13.

Da die Deckfläche 7 und die unteren Bereiche des Zylinderblocks 1, anders als die Kolbenlaufbahn 3 nicht für die Beschichtung mit einer aufgespritzten Schicht vorbereitet sind, ist die Haftung des Oversprays 13 weniger gut als die Haftung der Schicht 5 auf der Kolbenlaufbahn 3.Since the top surface 7 and the lower regions of the cylinder block 1, unlike the piston raceway 3, are not prepared for coating with a sprayed-on layer, the adhesion of the overspray 13 is less good than the adhesion of the layer 5 on the piston raceway 3.

Zu der schlechteren Haftung des Oversprays 13 auf dem Substrat 1 trägt auch der weitere Weg, den der Strahl von der Strahllanze bis zum Auftreffen beispielsweise auf den unteren Bereichen des Zylinderblocks 1 zurücklegt bei. Im Ergebnis lässt sich festhalten, dass der Overspray weniger gut an der Oberfläche des Werkstücks 1 als die Schicht 5 an der Kolbenlaufbahn 3 anhaftet.To the worse adhesion of the overspray 13 on the substrate 1 also contributes to the further path, the jet travels from the jet lance to hitting, for example, on the lower portions of the cylinder block 1 at. As a result, it can be stated that the overspray adheres less well to the surface of the workpiece 1 than the layer 5 on the piston raceway 3.

Der Overspray 13 muss von dem Werkstück 1 entfernt werden, da er sich andernfalls während des Betriebs des Verbrennungsmotors lösen und in den Ölkreislauf des Verbrennungsmotors gelangen könnte. Daraus kann ein erhöhter Verschleiß oder kapitale Folgeschäden resultieren. Auch im Bereich der Deckfläche 7 muss der Overspray 13 entfernt werden, da die Zylinderkopfdichtung nur dann aufgelegt werden kann, wenn die Deckfläche 7 plan ist und keine Aufwürfe in Form von Overspray 13 mehr aufweist.The overspray 13 must be removed from the workpiece 1, otherwise it will fail during operation of the workpiece Solve internal combustion engine and could get into the oil circuit of the internal combustion engine. This can result in increased wear or major consequential damage. Also in the area of the top surface 7 of the overspray 13 must be removed, since the cylinder head gasket can only be placed when the top surface 7 is flat and has no jarring in the form of overspray 13 more.

Erfindungsgemäß ist nun vorgesehen, den Overspray durch einen oder mehrere Flüssigkeitsstrahlen 15 abzutragen, wobei dieser Flüssigkeitsstrahl 15 aus einer oder mehreren Düsen 17 der Strahllanze 9 austritt.According to the invention, it is now provided to remove the overspray by one or more liquid jets 15, this liquid jet 15 emerging from one or more nozzles 17 of the jet lance 9.

In der in Figur 1 dargestellten Position der Strahllanze 9 wird der Overspray an der Deckfläche 7 des Zylinderblocks 1 abgetragen. Wie aus dieser Darstellung sehr deutlich hervorgeht, ist ein zweiter Winkel β zwischen dem Flüssigkeitsstrahl 15 und der Deckfläche 7 deutlich kleiner als 90°, er beträgt etwa 30° bis 40°.In the in FIG. 1 illustrated position of the jet lance 9, the overspray on the top surface 7 of the cylinder block 1 is removed. As is very clear from this illustration, a second angle β between the liquid jet 15 and the top surface 7 is significantly smaller than 90 °, it is about 30 ° to 40 °.

Ein erster Winkel α, der den Winkel zwischen einer von der Drehachse (Z-Achse) und einer von der R-Achse aufgespannten Ebene angibt ist in den Figuren nicht sichtbar und daher nicht eingetragen.A first angle α, which indicates the angle between a plane defined by the axis of rotation (Z axis) and a plane spanned by the R axis, is not visible in the figures and is therefore not registered.

Erfindungsgemäß ist vorgesehen, dass der Flüssigkeitsstrahl 15 nicht senkrecht auf den Overspray 13 auftritt, sondern möglichst unter einem kleinen Winkel, das heißt flach, auf die Werkstückoberfläche auftrifft. Dadurch wird erreicht, dass der Flüssigkeitsstrahl 15 gewissermaßen wie ein Keil zwischen den Overspray 13 und die Deckfläche 7 eindringt und dadurch der Overspray von der Deckfläche 7 abgeschält wird. Dadurch wird die Geschwindigkeit mit der der Overspray 13 entfernt deutlich erhöht und es genügt ein verhältnismäßig geringer Betriebsdruck von beispielsweise 28 MPa, um eine zuverlässige und rasche Entfernung des Oversprays zu gewährleisten.According to the invention, it is provided that the liquid jet 15 does not occur perpendicularly to the overspray 13, but if possible impinges on the workpiece surface at a small angle, that is to say flat. This ensures that the liquid jet 15 penetrates to a certain extent like a wedge between the overspray 13 and the top surface 7 and thereby the overspray is peeled off from the top surface 7. As a result, the speed at which the overspray 13 is removed is significantly increased and a relatively low operating pressure of, for example, 28 MPa is sufficient to ensure a reliable and rapid removal of the overspray.

Der Winkel unter dem der Flüssigkeitsstrahl 15 auf die Oberfläche des Werkstücks 1 auftrifft, wird durch den ersten Winkel α und den zweiten Winkel β bestimmt.The angle at which the liquid jet 15 strikes the surface of the workpiece 1 is determined by the first angle α and the second angle β.

Die Strahllanze 9 muss so weit oberhalb der Deckfläche 7 positioniert sein, dass der Strahl 15 nicht mehr in die Bohrung 3 gelangt, sondern ausschließlich auf der Deckfläche auftrifft.The jet lance 9 must be positioned so far above the top surface 7 that the jet 15 no longer enters the bore 3, but impinges exclusively on the top surface.

In Versuchen hat sich erwiesen, dass Winkel α und/oder β > 5° ausreichen, um die gewünschte Schälwirkung oder Spaltwirkung des Flüssigkeitsstrahls 15 zu erreichen. Herkömmliche Abtragverfahren, die mit einem Hochdruckwasserstrahl arbeiten, richten den Wasserstrahl diffus auf die abzutragende Schicht, hier das Overspray 13, und zertrümmern mit Hilfe eines sehr hohen Wasserdrucks den Overspray 13. Diese Vorgehensweise ist sehr viel energieintensiver, erfordert höhere bauliche Aufwendungen wegen des höheren Betriebsdrucks. Demgegenüber hat das erfindungsgemäße Verfahren noch den weiteren Vorteil, dass die Abtragrate deutlich erhöht ist.In experiments, it has been found that angles α and / or β> 5 ° are sufficient to achieve the desired peeling effect or splitting action of the liquid jet 15. Conventional erosion processes using a high-pressure water jet direct the water jet diffusely onto the layer to be removed, here the overspray 13, and destroy the overspray 13 by means of a very high water pressure. This procedure is much more energy-intensive and requires higher construction costs because of the higher operating pressure , In contrast, the inventive method has the further advantage that the removal rate is significantly increased.

Es versteht sich von selbst, dass die Austrittsrichtung der Düse 17 entsprechend der zu bearbeitenden Werkstückoberfläche, hier die Deckfläche 7, entsprechend gewählt und ausgerichtet werden muss, so dass der erfindungsgemäße kleine Winkel zwischen der zu bearbeitenden Oberfläche und dem Sprühmittelstrahl 15 gewährleistet ist.It goes without saying that the discharge direction of the nozzle 17 according to the workpiece surface to be machined, here the top surface 7, must be selected and aligned accordingly, so that the inventive small angle between the surface to be machined and the spray jet 15 is ensured.

Wenn man beispielsweise mit der gleichen Sprühlanze 9 in die Kolbenlaufbahn 3 so weit eintaucht, bis der Sprühmittelstrahl 15 auf den Overspray 13 am unteren Ende des Zylinderblocks 1 auftrifft, dann würde dieser Sprühmittelstrahl unter einem Winkel von etwa 60° auf den Overspray auftreffen. Dadurch würde die Schälwirkung des erfindungsgemäßen Verfahrens gemindert und insofern würde das erfindungsgemäße Verfahren nicht seine optimale Leistungsfähigkeit erzielen.If, for example, with the same spray lance 9 so far immersed in the piston raceway 3, until the Sprühmittelstrahl 15 impinges on the overspray 13 at the lower end of the cylinder block 1, then this spray jet would impinge at an angle of about 60 ° to the overspray. As a result, the peeling effect of the method according to the invention would be reduced and to that extent the method according to the invention would not achieve its optimum performance.

In Figur 1 ist nur eine Düse 17 und ein Sprühmittelstrahl 15 dargestellt. Es ist selbstverständlich auch möglich, mehrere über den Umfang verteilte und in Figur 1 nicht dargestellte Düsen 17, die, wenn auch über den Umfang versetzt unter dem gleichen Winkel β auf die Deckfläche 7 gerichtet sind, vorzusehen. Eine solche Gruppe von gleichgerichteten Düsen 17 wird nachfolgend als Düsenregister bezeichnet.In FIG. 1 only one nozzle 17 and one spray jet 15 are shown. It is of course also possible, several distributed over the circumference and in FIG. 1 not shown nozzles 17, which, although offset over the circumference at the same angle β directed to the top surface 7, provide. Such a group of rectified nozzles 17 will be referred to as a nozzle register hereinafter.

Wenn man nun im Sinne des erfindungsgemäßen Verfahrens den Overspray 13 am unteren Ende des Zylinderblocks abschälen beziehungsweise abtragen will, müssen die Düsen 17 anders ausgerichtet werden. Dies wird deutlich an den Figuren 2 und 3, die jeweils verschiedene Ausgestaltungen des unteren Endes einer Kolbenlaufbahn 3 und der angrenzenden Bereiche mit Overspray 13 darstellen. Die Figuren 2 und 3 sollen verdeutlichen, dass verschiedenste Geometrien und Konturen an das Ende der Zylinderlaufbahn 3 angrenzenden Gebiete Oberflächen des Werkstücks 1 möglich sind und infolgedessen auch Art, Größe und Ausprägung des Oversprays entsprechend verschieden sein können.If one now wants to peel off or remove the overspray 13 at the lower end of the cylinder block in the sense of the method according to the invention, the nozzles 17 must be aligned differently. This becomes clear to the FIGS. 2 and 3 , each representing different embodiments of the lower end of a piston raceway 3 and the adjacent areas with overspray 13. The FIGS. 2 and 3 are intended to illustrate that a wide variety of geometries and contours on the end of the cylinder barrel 3 adjacent areas surfaces of the workpiece 1 are possible and consequently the nature, size and nature of the overspray can be correspondingly different.

Um beispielsweise den in Figur 3 dargestellten Overspray 13 bestmöglich nach dem erfindungsgemäßen Verfahren abtragen zu können, ist in Figur 4 ein zweites Ausführungsbeispiel einer Sprühlanze 9 dargestellt. Bei diesem Ausführungsbeispiel einer Sprühmittellanze 9 ist die Düse 17 aufwärts gerichtet und zwar so, dass der Sprühmittelstrahl 15 unter einem zweiten Winkel β von etwa 45° auf die Oberfläche des Werkstücks in dem Bereich, in dem Overspray an dem Werkstück 1 vorhanden ist, auftrifft. In diesem Fall ist der zweite Winkel β zwischen dem Strahl 5 und der Werkstückoberfläche größer als bei dem Ausführungsbeispiel gemäß Figur 1, was der Kontur des Werkstücks 1 geschuldet ist.For example, the in FIG. 3 shown overspray 13 best possible to ablate by the method according to the invention, is in FIG. 4 a second embodiment of a spray lance 9 is shown. In this embodiment of a spray lance 9, the nozzle 17 is directed upward such that the spray jet 15 impinges on the surface of the workpiece at a second angle β of about 45 ° in the region where overspray is present on the workpiece 1. In this case, the second angle β between the beam 5 and the workpiece surface is larger than in the embodiment according to FIG FIG. 1 , which is due to the contour of the workpiece 1.

Bei dem Ausführungsbeispiel gemäß Figur 4 ist der Overspray 13 in einer Vertiefung des Werkstücks 1 angebracht, so dass Strahl 15 nur dann alle vom Overspray 13 bedeckten Bereiche des Werkstücks 1 erreicht, wenn er etwas steiler auf die Werkstückoberfläche gerichtet ist. Da jedoch die Stelle an welcher der Strahl 15 beginnt, den Overspray 13 abzutragen, am weitesten von der Kolbenlaufbahn 3 entfernt ist, ist hier die Dicke des Oversprays 13 minimal und die Haftung des Oversprays 13 am schlechtesten. Daher ist es auch mit diesen etwas größeren Winkel zwischen dem Strahl 15 und der Werkstückoberfläche erfindungsgemäß gut möglich, den Overspray abzuschälen. Dabei platzen verhältnismäßig große Stücke von Overspray 13 von der Oberfläche des Werkstücks 1 ab, so dass sich insgesamt ein sehr effizientes und wirksames Abtragen des Oversprays 13 trotz des Winkels von etwa 45° zwischen dem Strahl 15 und der Werkstückoberfläche einstellt.In the embodiment according to FIG. 4 is the overspray 13 mounted in a recess of the workpiece 1, so that beam 15 only reaches all of the overspray 13 covered areas of the workpiece 1, if he is a little steeper on the Workpiece surface is directed. However, since the point at which the jet 15 begins to remove the overspray 13 is farthest from the piston barrel 3, the thickness of the overspray 13 is minimal and the adhesion of the overspray 13 is the worst. Therefore, it is also possible with these slightly larger angle between the beam 15 and the workpiece surface according to the invention to peel off the overspray. In this case, relatively large pieces of overspray 13 burst from the surface of the workpiece 1, so that overall sets a very efficient and effective removal of overspray 13 despite the angle of about 45 ° between the beam 15 and the workpiece surface.

In Figur 5 ist exemplarisch und stark vergrößert ein solcher abgeplatzter Partikel von Overspray 13 dargestellt. Bei der Auswertung praktisch durchgeführter Versuche hat sich ergeben, dass Partikel mit einer Länge von etwa 10 mm und einer Breite von etwa 5 mm Partikel abplatzen und somit der Overspray 13 nicht zertrümmert wird, sondern wie auch die Figuren 1 und 4 veranschaulichen, abgeschält wird. Der erfindungsgemäße Wirkungsmechanismus basiert darauf, dass der Strahl 15 zwischen Overspray 13 und dem Substrat beziehungsweise der Werkstückoberfläche 1 in der Art eines "Spaltkeils" eindringt.In FIG. 5 is exemplified and greatly enlarged such a chipped particle of overspray 13 is shown. In the evaluation of practical experiments has been found that particles with a length of about 10 mm and a width of about 5 mm particles flake off and thus the overspray 13 is not shattered, but like the FIGS. 1 and 4 illustrate, is peeled off. The mechanism of action according to the invention is based on the fact that the jet 15 penetrates between overspray 13 and the substrate or the workpiece surface 1 in the manner of a "splitting wedge".

Es wäre naturgemäß auch möglich, in eine Lanze 9 mehrere Register von Düsen 17 zu integrieren, die jeweils unter unterschiedlichen Winkeln aus der Lanze 9 austreten. Diese verschiedenen Register könnten dann entweder gleichzeitig oder nacheinander aktiviert werden, je nachdem wie die Oberfläche des Werkstücks verläuft. Dadurch kann immer ein optimaler Winkel zwischen dem Strahl 15 und der Werkstückoberfläche erzielt werden, auch wenn die Düsen 17 nicht verschwenkbar, sondern starr in der Lanze 9 eingebaut sind.It would of course also be possible to integrate in a lance 9 more registers of nozzles 17, which emerge in each case at different angles from the lance 9. These different registers could then be activated either simultaneously or sequentially, depending on how the surface of the workpiece passes. As a result, it is always possible to achieve an optimum angle between the jet 15 and the workpiece surface, even if the nozzles 17 are not pivotable but rigidly mounted in the lance 9.

Wenn die verschiedenen Düsenregister einzeln aktiviert werden können, können gleichzeitig auch noch der Sprühmittelbedarf und der Bedarf an Antriebleistung minimiert werden.If the different nozzle registers can be activated individually, at the same time the spray requirement and the drive power requirement can be minimized.

In Figur 6 ist ein solches Ausführungsbeispiel einer solchen Lanze 9 dargestellt. Diese Lanze 9 ragt durch die gesamte Kolbenlaufbahn 3 hindurch. Das erste Register von Düsen 17.1 ist auf den Overspray an der Deckfläche 7 gerichtet, während ein zweites Register von Düsen 17.2 von unten auf den Overspray in dem Bereich unterhalb der Kolbenlaufbahn 3 gerichtet ist. Diese Lanze 9 ist gewissermaßen die Kombination der in den Figuren 1 und 4 dargestellten Lanzen. Dadurch ist es möglich, den Overspray 13 oberhalb und unterhalb der Kolbenlaufbahn 3 gleichzeitig und mit hoher Effektivität zu entfernen, was die Taktzeiten verringert und das erfindungsgemäße Verfahren noch wirtschaftlicher macht.In FIG. 6 Such an embodiment of such a lance 9 is shown. This lance 9 protrudes through the entire piston raceway 3 therethrough. The first register of nozzles 17.1 is directed to the overspray on the top surface 7, while a second register of nozzles 17.2 is directed from below to the overspray in the region below the piston barrel 3. This lance 9 is to a certain extent the combination of in the FIGS. 1 and 4 illustrated lances. This makes it possible to remove the overspray 13 above and below the piston barrel 3 at the same time and with high efficiency, which reduces the cycle times and makes the inventive method even more economical.

Es ist auch möglich, die Düsen 17 schwenkbar in der Lanze 9 zu lagern, so dass sie entsprechend der aktuellen Position der Lanze 9 auf die Oberfläche des Werkstücks 1 gerichtet werden können, so dass der Strahl mit einem möglichst kleinen Winkel auf der Oberfläche des Werkstücks 1 auftrifft. Dadurch wird eine bestmögliche Schälwirkung oder Spaltwirkung zwischen dem Overspray 13 und dem Werkstück erzielt, so dass das Overspray 13 rasch und sicher mit geringem Strahlmittel- und Energieaufwand entfernt werden kann.It is also possible to mount the nozzles 17 pivotably in the lance 9, so that they can be directed to the surface of the workpiece 1 according to the current position of the lance 9, so that the beam with the smallest possible angle on the surface of the workpiece 1 hits. As a result, the best possible peeling effect or splitting effect between the overspray 13 and the workpiece is achieved, so that the overspray 13 can be removed quickly and safely with low blasting agent and energy expenditure.

Durch die Verwendung des in der Maschine befindlichen Kühlschmierstoffes für die mechanische Bearbeitung, gewinnt das hydromechanische Abtragen von Overspray 13 weiter an Wirtschaftlichkeit. Es ist kein separater Kreislauf und keine Waschmaschine zwischen den Prozessen erforderlich, sondern es kann mit ein und demselben Fluid sowohl bei der Zerspanung als beim Abtragen des Oversprays 13 gearbeitet werden.By using the machine-installed cooling lubricant for mechanical processing, the hydromechanical removal of overspray 13 continues to gain economic efficiency. It is not a separate circuit and no washing machine required between the processes, but it can be worked with one and the same fluid both in the machining than in the removal of overspray 13.

Eine lokale Druckanpassung an den Verlauf der Topographie ist durch einen automatisierten Zyklus möglich. Dies ist dann erforderlich, wenn der Verlauf der zu strahlenden Werkstückoberfläche ungünstig ist.A local pressure adjustment to the course of the topography is possible through an automated cycle. This is then required if the course of the workpiece surface to be blasted is unfavorable.

Strahlparameter am Ausführungsbeispiel: Druck: 28 MPa Volumenstrom /Düse: 5,6 l/min Anzahl der Düsen: 6 Düsendurchmesser: 0,9 mm Gesamtvolumenstrom: 34 l/min Düsenabstand: ≥ 15 mm Material der Düsen: Saphir Beam parameters in the exemplary embodiment: Print: 28 MPa Flow rate / nozzle: 5.6 l / min Number of nozzles: 6 Nozzle diameter: 0.9 mm Total current: 34 l / min Nozzle distance: ≥ 15 mm Material of the nozzles: sapphire

Claims (22)

  1. Method for removing the overspray (13) of a coating (5) sprayed onto a workpiece (1), in which the at least one fluid jet (15) of a jet lance (9) is directed, as a hydrodynamic wedge, into the dividing plane between workpiece (1) and overspray (13) on the regions of the workpiece (1) coated with overspray (13).
  2. Method according to claim 1, characterised in that the at least one fluid jet (15) is directed at the region of the workpiece (1) coated with overspray (13) at an angle of less than 90°, preferably less than 30° and particularly preferably less than 10°, and greater than 5°.
  3. Method according to claim 1 or 2, characterised in that the fluid jet (15) is guided from the uncoated regions of the workpiece (1) to the regions coated with overspray (13).
  4. Method according to claim 1, 2 or 3, characterised in that the jet lance (9) and/or the exit direction of the at least one fluid jet (15) is controlled depending on the orientation of the surface of the workpiece (1) in the regions coated with overspray (13).
  5. Method according to claim 1, 2 or 3, characterised in that the jet lance (9) performs a rotary movement (11).
  6. Method according to one of the preceding claims, characterised in that the jet lance (9) is arranged coaxially to a cylinder bore (3).
  7. Method according to one of the preceding claims, characterised in that the direction of at least one fluid jet (15) encloses a first angle (α) with a plane (Z-R plane) spanned by the axis of rotation (Z) of the jet lance (9) and a radial jet (R), and that the first angle (α) is greater than 5° and less than 85°.
  8. Method according to one of the preceding claims, characterised in that the direction of at least one fluid jet (15) encloses a second angle (ß) with a plane (X-Y plane) which is arranged perpendicular to the radial jet (R), and that the second angle (ß) is greater than 5° and less than 85°.
  9. Method according to one of the preceding claims, characterised in that at least one nozzle (17) of the jet lance (9) can be swivelled in a plane (Z-R plane) spanned by the axis of rotation (Z) of the jet lance (9) and a radial jet (R) and/or a plane (X-Y plane) which is arranged perpendicular to the radial jet (R).
  10. Method according to one of the preceding claims, characterised in that a cooling lubricant, preferably a cooling lubricant which can be mixed with water and/or a synthetic cooling lubricant, is used as fluid.
  11. Method according to one of the preceding claims, characterised in that the cooling lubricant is fed to the nozzles (17) which form the fluid jet (15) with a pressure in a range between 15 MPa and 60 MPa, preferably in a range between 20 MPa and 50 MPa, and particularly preferably in a range between 25 MPa and 40 MPa.
  12. Method according to one of the preceding claims, characterised in that the pressure with which the cooling lubricant is fed to the nozzles (17) of the jet lance (9) is controlled depending on the rotary and/or translatory position of the nozzles (17).
  13. Method according to one of the preceding claims, characterised in that the volume flow of the cooling lubricant delivered through the nozzles (17) of the jet lance (9) is controlled depending on the rotary and/or translatory position of the nozzles (17).
  14. Method according to one of the preceding claims, characterised in that, following one of the methods according to one of the preceding claims, the coated functional surface (5) is honed and the edges of the honed functional surface (5) are subsequently given a bevel.
  15. Method according to one of the claims 1 to 14, characterised in that, as the overspray is being removed, the coated functional surface (5) is cooled by at least one fluid jet (15).
  16. Method according to one of the claims 1 to 14, characterised in that the coated functional surface (5) is actively or passively cooled and honed, that the overspray (13) is then removed using a method according to one of the claims 1 to 10, and that the edges of the honed functional surface (5) are subsequently given a bevel.
  17. Jet lance (9) for carrying out one of the preceding methods for removing overspray (13) with at least one cooling lubricant connection and with at least one nozzle (17), characterised in that the at least one nozzle (17) of the jet lance (9) encloses a first angle (α) with a plane (Z-R plane) spanned by the axis of rotation (Z) of the jet lance (9) and a radial jet (R) and that the first angle (α) is greater than 5° and less than 85°.
  18. Jet lance (9) according to claim 17, characterised in that the at least one nozzle (17) of the jet lance (9) encloses a second angle (ß) with the axis of rotation (Z) of the jet lance (9) and a plane (X-Y plane) which is arranged perpendicular to the radial jet (R), and that the second angle (ß) is greater than 5° and less than 85°.
  19. Jet lance (9) according to claim 17 or 18, characterised in that the at least one nozzle (17) of the jet lance (9) can be swivelled in order to adjust the first angle (α) and/or the second angle (ß).
  20. Jet lance (9) according to one of the claims 17 to 19, characterised in that several nozzles (17) are provided, that the nozzles (17) are aligned at different first angles (α) and/or second angles (ß).
  21. Jet lance (9) according to one of the claims 17 to 20, characterised in that the nozzles (17) can be switched on and off individually.
  22. Jet lance (9) according to one of the claims 17 to 21, characterised in that the nozzles (19) are arranged spaced at a distance from one another in the direction of the Z-axis, so that the overspray (13) can be removed simultaneously at both ends of the coated functional surface (5).
EP11703825.7A 2010-02-09 2011-02-03 Method for removing overspray of thermal spray coatings Active EP2533911B1 (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
DE102010007224A DE102010007224A1 (en) 2010-02-09 2010-02-09 Method for removing overspray of thermal spray coatings
PCT/EP2011/000483 WO2011098229A1 (en) 2010-02-09 2011-02-03 Method for removing overspray of thermal spray coatings

Publications (2)

Publication Number Publication Date
EP2533911A1 EP2533911A1 (en) 2012-12-19
EP2533911B1 true EP2533911B1 (en) 2015-12-16

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EP11703825.7A Active EP2533911B1 (en) 2010-02-09 2011-02-03 Method for removing overspray of thermal spray coatings

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US (1) US20130061885A1 (en)
EP (1) EP2533911B1 (en)
JP (1) JP2013518707A (en)
KR (1) KR20120118500A (en)
CN (1) CN102802819B (en)
DE (1) DE102010007224A1 (en)
HU (1) HUE027130T2 (en)
PL (1) PL2533911T3 (en)
WO (1) WO2011098229A1 (en)

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DE102017002078A1 (en) * 2017-03-04 2018-09-06 Man Truck & Bus Ag Internal combustion engine and method for producing a crankcase and / or a cylinder liner for an internal combustion engine
CN109174764A (en) * 2018-09-14 2019-01-11 凌云工业股份有限公司上海凌云汽车研发分公司 A kind of quick de-plating method of coating thermoforming steel
CN110695039A (en) * 2019-10-11 2020-01-17 苏州盛达飞智能科技股份有限公司 Foam waste collecting device and using method thereof
JP6907390B1 (en) * 2020-07-08 2021-07-21 株式会社スギノマシン Cleaning method and washing machine

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Also Published As

Publication number Publication date
CN102802819B (en) 2015-07-01
JP2013518707A (en) 2013-05-23
WO2011098229A1 (en) 2011-08-18
CN102802819A (en) 2012-11-28
KR20120118500A (en) 2012-10-26
HUE027130T2 (en) 2016-10-28
DE102010007224A1 (en) 2011-08-11
EP2533911A1 (en) 2012-12-19
US20130061885A1 (en) 2013-03-14
PL2533911T3 (en) 2016-09-30

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