EP2533911B1 - Verfahren zum abtragen von overspray thermischer spritzschichten - Google Patents

Verfahren zum abtragen von overspray thermischer spritzschichten 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
Authority
EP
European Patent Office
Prior art keywords
jet
overspray
lance
angle
plane
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Active
Application number
EP11703825.7A
Other languages
German (de)
English (en)
French (fr)
Other versions
EP2533911A1 (de
Inventor
Wolfgang Treutmann
Gerhard Flores
Clemens Maria Verpoort
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Ford Werke GmbH
Gehring Technologies GmbH and Co KG
Original Assignee
Ford Werke GmbH
Gehring Technologies GmbH and Co KG
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Ford Werke GmbH, Gehring Technologies GmbH and Co KG filed Critical Ford Werke GmbH
Publication of EP2533911A1 publication Critical patent/EP2533911A1/de
Application granted granted Critical
Publication of EP2533911B1 publication Critical patent/EP2533911B1/de
Active legal-status Critical Current
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Classifications

    • 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

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Coating By Spraying Or Casting (AREA)
  • Cleaning By Liquid Or Steam (AREA)
  • Nozzles (AREA)
EP11703825.7A 2010-02-09 2011-02-03 Verfahren zum abtragen von overspray thermischer spritzschichten Active EP2533911B1 (de)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
DE102010007224A DE102010007224A1 (de) 2010-02-09 2010-02-09 Verfahren zum Abtragen von Overspray thermischer Spritzschichten
PCT/EP2011/000483 WO2011098229A1 (de) 2010-02-09 2011-02-03 Verfahren zum abtragen von overspray thermischer spritzschichten

Publications (2)

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

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EP11703825.7A Active EP2533911B1 (de) 2010-02-09 2011-02-03 Verfahren zum abtragen von overspray thermischer spritzschichten

Country Status (9)

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

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DE102011120554A1 (de) 2011-02-03 2012-08-09 Daimler Ag Verfahren und Vorrichtung zur thermischen Beschichtung eines Bauteils mit einer Durchgangsöffnung
DE102017002078A1 (de) * 2017-03-04 2018-09-06 Man Truck & Bus Ag Brennkraftmaschine und Verfahren zum Herstellen eines Kurbelgehäuses und/oder einer Zylinderlaufbuchse für eine Brennkraftmaschine
CN109174764A (zh) * 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 一种镀层热成型钢的快速去镀层方法
CN110695039A (zh) * 2019-10-11 2020-01-17 苏州盛达飞智能科技股份有限公司 一种泡棉废料收集装置及其使用方法
JP6907390B1 (ja) * 2020-07-08 2021-07-21 株式会社スギノマシン 洗浄方法および洗浄機

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Also Published As

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

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