EP2861364A2 - Pièce moulée métallique et procédé de fabrication d'une pièce moulée métallique - Google Patents

Pièce moulée métallique et procédé de fabrication d'une pièce moulée métallique

Info

Publication number
EP2861364A2
EP2861364A2 EP13726758.9A EP13726758A EP2861364A2 EP 2861364 A2 EP2861364 A2 EP 2861364A2 EP 13726758 A EP13726758 A EP 13726758A EP 2861364 A2 EP2861364 A2 EP 2861364A2
Authority
EP
European Patent Office
Prior art keywords
casting
cast
cast component
sections
iron
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.)
Withdrawn
Application number
EP13726758.9A
Other languages
German (de)
English (en)
Inventor
Rüdiger BÄHR
Ingolf Behm
Stefan Scharf
Sven RÖPKE
Joachim SCHNEIBEL
Manja Krüger
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.)
Volkswagen AG
Original Assignee
Volkswagen AG
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 Volkswagen AG filed Critical Volkswagen AG
Publication of EP2861364A2 publication Critical patent/EP2861364A2/fr
Withdrawn legal-status Critical Current

Links

Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D19/00—Casting in, on, or around objects which form part of the product
    • B22D19/009—Casting in, on, or around objects which form part of the product for casting objects the members of which can be separated afterwards
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D19/00—Casting in, on, or around objects which form part of the product
    • B22D19/04—Casting in, on, or around objects which form part of the product for joining parts
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D19/00—Casting in, on, or around objects which form part of the product
    • B22D19/16—Casting in, on, or around objects which form part of the product for making compound objects cast of two or more different metals, e.g. for making rolls for rolling mills
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F02—COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
    • F02F—CYLINDERS, PISTONS OR CASINGS, FOR COMBUSTION ENGINES; ARRANGEMENTS OF SEALINGS IN COMBUSTION ENGINES
    • F02F1/00—Cylinders; Cylinder heads 
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
    • F05C—INDEXING SCHEME RELATING TO MATERIALS, MATERIAL PROPERTIES OR MATERIAL CHARACTERISTICS FOR MACHINES, ENGINES OR PUMPS OTHER THAN NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES
    • F05C2201/00—Metals
    • F05C2201/02—Light metals
    • F05C2201/028—Magnesium
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
    • F05C—INDEXING SCHEME RELATING TO MATERIALS, MATERIAL PROPERTIES OR MATERIAL CHARACTERISTICS FOR MACHINES, ENGINES OR PUMPS OTHER THAN NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES
    • F05C2201/00—Metals
    • F05C2201/04—Heavy metals
    • F05C2201/0433—Iron group; Ferrous alloys, e.g. steel
    • F05C2201/0448—Steel
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
    • F05C—INDEXING SCHEME RELATING TO MATERIALS, MATERIAL PROPERTIES OR MATERIAL CHARACTERISTICS FOR MACHINES, ENGINES OR PUMPS OTHER THAN NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES
    • F05C2201/00—Metals
    • F05C2201/90—Alloys not otherwise provided for
    • F05C2201/903—Aluminium alloy, e.g. AlCuMgPb F34,37

Definitions

  • the invention relates to a metallic cast component, in particular for parts of a
  • Internal combustion engine or a reciprocating compressor such as a piston, a cylinder head, a transmission housing, a crankcase and / or another housing is provided.
  • the invention relates to a method for producing a metallic cast component, in particular for parts of an internal combustion engine or a reciprocating compressor such as a piston, a cylinder head, a gear housing, a crankcase and / or another housing, which consists of a cast material or more cast materials, such as cast iron and or ferrous aluminide and / or light metal, in which a first portion of the cast component is produced in a first casting operation and a second portion of the cast component is produced in a second casting operation.
  • a method for producing a metallic cast component in particular for parts of an internal combustion engine or a reciprocating compressor such as a piston, a cylinder head, a gear housing, a crankcase and / or another housing, which consists of a cast material or more cast materials, such as cast iron and or ferrous aluminide and / or light metal, in which a first portion of the cast component is produced in a first casting operation and a second portion of the cast component is produced in a second casting operation.
  • Verbundgussbauteils comprises an at least two-stage casting process in a casting, wherein in a first process step, a casting of a first material in the casting device is produced by casting and then in a second process step, the composite casting is finished by replacing one or more cores the first step during the
  • Cooling of the first material cores are changed geometry used in the pouring device before the casting process is completed in the second process step by pouring the second material.
  • DE 100 02 440 A1 discloses a primer layer of a nickel-aluminum alloy and a nickel-titanium alloy to be applied to a cast part first, the cast part.
  • a cylinder head with support structures for stabilizing a jacket made of light metal shows the document EP 2 024 1 16 B1. The loads of cast components for internal combustion engines increased by
  • the invention has the object, a cast component and a method for producing a cast component of the type mentioned in such a way that the cast component meets the increased requirements.
  • the first embodiment relates to a cast component which exclusively comprises an iron aluminide.
  • the second embodiment relates to a cast component which comprises one of at least two
  • Sections existing composite casting is, each of the sections has a different density with respect to the casting material. It turned out that too
  • Cast component which is made entirely of ferric aluminide, which meets the increased requirements.
  • Iron aluminide has characteristics similar to those of cast iron, particularly in terms of temperature resistance and strength, but the density of iron aluminide is similar to that of a light metal such as aluminum.
  • a lightweight and at the same time durable cast component was created.
  • the cast component may also be a composite cast component, which consists of at least two sections, also called casting sections. These sections are created one after the other.
  • one of the sections is made of a more durable, denser material, such as a cast iron and / or an iron aluminide and / or a
  • the other section is ideally made of a lighter material, such as ferric aluminide and / or a light metal.
  • ferric aluminide or a combination of a durable material with a lightweight material it is possible to produce a cast component that meets the increased requirements.
  • cast iron cast iron with aluminide, aluminide with aluminum and aluminum with magnesium have proven. This is mainly due to the fact that these materials have similar thermal expansion coefficients, which reduces the formation of gaps and residual stresses.
  • the casting materials cast iron and aluminum may indeed form a gap between the components cooled to room temperature, but this is not a problem since the material with the lower density heats up when the cast component is heated
  • the sections may also be referred to as casting areas, with a section made earlier in terms of time also being called a cast part.
  • a Eingussteil which is provided in an at least partially solidified state for placement in another casting tool is also referred to as a depositor.
  • the first section, the cast part or the insert can be produced from both the resistant material and from the light material. It has proven to be particularly practical in production that the first section produced is made of the durable material. In particular, in an intermediate storage or the introduction into another casting tool this is easier to handle, because it is less sensitive.
  • iron aluminide the use of Fe x Al, in particular of Fe 3 AI has proven to be particularly favorable.
  • iron aluminide in particular as a primer layer, simple casting plants and simple casting techniques can be used, as a targeted adjustment of certain microstructures, especially in the light metals such as aluminum, is not necessary.
  • secondary raw materials such as recycled aluminum.
  • a casting subsequent process of heat treatment can be omitted.
  • the coating is at most 20 millimeters thick, but preferably thinner than 2 millimeters, and thus substantially thinner than the section of a section.
  • Iron aluminides are characterized by extremely high strengths, even at high temperatures. Compared with classic steels, they have a significantly reduced density and, at the same time, very good corrosion resistance
  • a further embodiment of the invention relates to a cast component, in which one of the sections of a combustion chamber and / or a gas line of an internal combustion engine
  • the first section is for example a boundary wall of a combustion chamber and comprises at least one outlet opening of the combustion chamber for exhaust gas.
  • the first produced section is an insert, which is at least partially surrounded by at least one second section. Since the portion defining the combustion chamber or an exhaust pipe of an internal combustion engine is subjected to higher stress than other portions of the cast component by temperature and / or pressure, this first portion is preferably made of a steel, cast iron, iron aluminide or high-strength light metal alloy.
  • the insert enclosing portion is also called shell casing.
  • the jacket housing is preferably made of an iron-aluminide or light metal.
  • An embodiment of the invention also relates to a cast component, in which the first section with respect to geometry, pressure and temperature resistance as a support member of
  • Cast components is executed.
  • Exterior surfaces of the casting provide additional stability, fatigue strength and rigidity to another section made from a lightweight, lower density material. Even by such a local reinforcement by partial use of high-strength materials, the specific power of an internal combustion engine can be increased.
  • a cast component for a cylinder head a separation of the different media-carrying channels by the combination of the light metals aluminum and magnesium take place.
  • this cast component can have individual cast iron surfaces for shielding from the hot gases of the combustion chamber and a cast iron or iron-aluminide support structure for increasing the rigidity or for reducing stress peaks.
  • An embodiment of the invention is that the first section is designed as a heat protection element or cooling element.
  • a heat protection element reflects the heat radiation so that it can not penetrate into the depth of the cast component.
  • Heat protection element also realize the function of a cooling element and dissipate heat targeted.
  • a cooling element heat exchangers with a large surface area are also referred to.
  • a section which is a boundary wall of at least one combustion chamber comprising at least one outlet opening of the combustion chamber for exhaust gas comprises an exhaust manifold.
  • Exhaust manifold according to the invention consists for example of a cast iron and / or an iron aluminide.
  • the invention also makes it possible to combine areas of the internal combustion engine that fulfill different functions in a cast component.
  • the cast component is a cylinder head or a cylinder housing, of which a portion is integrally formed with at least a part of a housing of a turbocharger. This makes it possible to reduce the number of parts and the assembly cost.
  • each section an independent water jacket is provided, in each of which a cooling fluid circulates.
  • a cooling fluid circulates.
  • independent casting process steps in particular by the use of a section as a depositor, a separation of the media-leading areas in a simple manner possible.
  • the separation of the media leading areas prevents corrosion as the cooling fluids in contact with different metals are separated.
  • the vibration resistance in the region of a water jacket or a gas exchange channel can by the formation of a
  • Support structure can be achieved.
  • the support structure is preferably made of an iron aluminide and is at least partially surrounded by an aluminum material.
  • cylinder heads made of cast iron are used.
  • Light metal such as aluminum are often used in passenger cars. These have the advantage of being light in weight. At higher temperatures, the strength of light metal decreases.
  • one section consists of a pressure-resistant material such as cast iron and the other section of a lightweight material, such as aluminum.
  • the elements of the cast component of a Cylinder heads which consist of pressure- or temperature-resistant materials, are for example the inlet and outlet channels.
  • Other elements for example conduits for cooling media or lubricants, are made of a light metal.
  • the cast body of the cylinder head consists partly or completely of this material.
  • iron aluminide is combined according to the invention with cast iron and / or a light metal.
  • a cast component which consists of a combination of the materials cast iron and
  • Alloy exists may form due to the different thermal expansion of the materials in the transition region columns.
  • the use according to the invention of iron aluminide as adhesion promoter layer between two sections makes it possible to improve the material bond in the transition region between different light metal alloys or between light metal and cast iron and thus reduce the tendency to fission, in particular during cooling after casting. This is achieved above all by applying the iron aluminide as a coating to an existing section before producing a further section.
  • a method is provided in which prior to a second casting operation on the first section a coating, in particular of iron aluminide as
  • Adhesive layer is applied.
  • a primer layer of iron aluminide it is possible to reduce the manufacturing costs compared to the prior art and to produce an improved cohesive connection between two sections in the casting. It is possible to use simple casting machines and casting techniques, since it is not necessary to deliberately adjust certain microstructures, in particular in light metals such as aluminum. In addition, it will be possible, even secondary raw materials, like again
  • the sections can be produced in a common casting tool. However, it has proved favorable that the sections are produced in separate casting tools, wherein the first section is arranged in the casting tool intended for the second or further casting operation before a second or further casting operation. In any case, the first cast and already partially or fully solidified section is surrounded by the second section. In this case, the sections connect materially.
  • Cast component is provided according to one of claims 1 to 6.
  • the coating is applied by means of casting, dipping, spraying and / or thermal spraying.
  • the coating forming a primer layer is ideally applied completely between the sections.
  • the coating is a liquid or solid material.
  • the coating and the section on which the coating is applied are charged statically in opposite directions for application. The improved by the coating
  • Bonding between the sections reduces the gap formation during the cooling of the cast component after the casting process.
  • the iron aluminide for the primer layer is provided as a coating, preferably in a solid phase, for example as a powder.
  • the application of the coating success preferably by means of thermal spraying, such as flame spraying, arc spraying or
  • the first section in particular a first section provided as a depositor of the cast component, is subjected to sandblasting prior to coating.
  • first casting material is used in the first casting process and a second casting material is used in the second casting process. This is the first one
  • the coating is a material connection with both the first and with the another section and thus forms the adhesion promoter layer.
  • This cohesive connection formed between the sections by means of a bonding agent layer has in particular during
  • Fig. 1 is a schematic representation of a first embodiment of a portion of a cast component
  • FIG. 2 shows a schematic representation of the section shown in FIG. 1 with the casting cores of a casting tool before the casting of a further section of the cast component;
  • FIG. 3 shows a schematic exploded view of the section shown in FIG. 1 and of the further section of the cast component formed during casting;
  • FIG. 4 shows a schematic representation of the cast component shown in FIG.
  • FIG. 5 shows a schematic representation of a cast component with two sections and a coating provided therebetween
  • FIG. 6 shows a schematic representation of a flow chart of the method for producing a cast component
  • Fig. 7 is a schematic representation of a combustion chamber of a
  • Fig. 8 is a schematic representation of a combustion chamber of a
  • FIG. 9 shows a schematic illustration of a second embodiment of a section of a cast component with a support structure
  • FIG. 10 shows a schematic representation of a third embodiment of a section of a cast component with an exhaust manifold.
  • FIGS. 1 to 6 show a method for producing a metallic cast component 1.
  • the cast component 1 shown by way of example here is a cylinder head of one not further
  • the cast component 1 is a hybrid cylinder head consisting of two different cast materials.
  • a first section 2 of the cast component 1 consists of cast iron or iron aluminide, while a second section 3 of the cast component 1 consists of iron aluminide or a light metal.
  • the first section 2 of the cast component 1 is produced in a first casting tool.
  • the first section 2 taken from the first casting tool (not shown) is shown inter alia in FIG.
  • the first section 2 is inserted into a second casting tool 5. From the second casting tool in Figure 2, only one oil core 6 for generating a cavity, which later serves to receive a lubricant, and a water core 7 shown.
  • the water core 7 generates in the second section 3 a cavity, also called water jacket 10, which can serve to receive a cooling medium or cooling fluid.
  • a water jacket 1 1 arranged in the first section 2 is independent of the water jacket 10 of the second section 3. This serves to reduce corrosion in the cylinder head.
  • the second section 3 of the cast component 1 is produced.
  • FIGS. 3 and 4 the complete cast component 1 with the first section 2 and the second section 3 can be seen.
  • a coating 12 is applied to the first section 2
  • the coating 12 is made of an iron aluminide and is preferably applied by thermal spraying. 8. The application of an iron-aluminide coating is dispensed with if the first section 2 and the second section 3 consist of an iron aluminide.
  • FIGS. 7 and 8 show the first section 2 in a first embodiment as a combustion chamber plate of a cylinder head.
  • the combustion chamber plate comprises two gas outlet channels 13, two gas inlet channels 14 and also a part of the already described water jacket 1 1.
  • the combustion chamber facing side is shown. This side is also called cylinder head surface 15 and has outlet openings 16 of the gas outlet channels 13 and inlet openings 17 of the gas inlet channels 14.
  • FIG. 9 shows a second embodiment of the cast component 1, in particular its first section 2.
  • This first section 2 comprises a support element 18
  • the second section 3 encloses the first section 2 and forms the
  • Shell casing a cylinder head, while the first portion 2 is designed as a combustion chamber plate with the cylinder head surface 15.
  • FIG. 10 shows a third embodiment of the cast component 1, in particular its first section 2.
  • This first section 2 comprises an exhaust manifold 19.
  • a housing of a turbocharger 20 is arranged on the exhaust manifold 19 by means of a screw connection.

Landscapes

  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Cylinder Crankcases Of Internal Combustion Engines (AREA)
  • Chemical & Material Sciences (AREA)
  • Combustion & Propulsion (AREA)
  • General Engineering & Computer Science (AREA)
  • Pistons, Piston Rings, And Cylinders (AREA)

Abstract

L'invention concerne une pièce moulée métallique (1), qui est prévue en particulier pour des pièces de moteurs à combustion interne ou des compresseurs à piston, telles que des pistons, des carters de transmission, des carters de moteur et d'autres carters et/ou des culasses. La pièce moulée (1) est constituée au moins sur certaines parties d'un aluminiure de fer et/ou une pièce moulée composite est pourvue d'au moins deux parties (2, 3), lesquelles sont constituées d'une fonte et/ou d'un aluminiure de fer et/ou d'un métal léger. L'invention concerne par ailleurs un procédé de fabrication d'une pièce moulée métallique (1), en particulier pour des pièces de moteurs à combustion interne ou de compresseurs à piston, telles que des pistons, des carters de transmission, des carters de moteur et d'autres carters et/ou des culasses, qui est constituée d'un ou de plusieurs matériaux de moulage tels que de la fonte et/ou un aluminiure de fer et/ou un métal léger, selon lequel une première partie (2) de la pièce moulée (1) est produite au cours d'une première opération de moulage et une autre partie (3) de la pièce moulée (1) est produite au cours d'une autre opération de moulage. Selon ce procédé, avant l'autre opération de moulage, un revêtement, en particulier en aluminiure de fer et/ou un alliage de nickel, est appliqué en tant que couche de promotion d'adhérence sur la première partie (2).
EP13726758.9A 2012-06-16 2013-05-29 Pièce moulée métallique et procédé de fabrication d'une pièce moulée métallique Withdrawn EP2861364A2 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
DE102012011992A DE102012011992A1 (de) 2012-06-16 2012-06-16 Metallisches Gussbauteil und Verfahren zur Herstellung eines metallischen Gussbauteils
PCT/EP2013/061112 WO2013186055A2 (fr) 2012-06-16 2013-05-29 Pièce moulée métallique et procédé de fabrication d'une pièce moulée métallique

Publications (1)

Publication Number Publication Date
EP2861364A2 true EP2861364A2 (fr) 2015-04-22

Family

ID=48576404

Family Applications (1)

Application Number Title Priority Date Filing Date
EP13726758.9A Withdrawn EP2861364A2 (fr) 2012-06-16 2013-05-29 Pièce moulée métallique et procédé de fabrication d'une pièce moulée métallique

Country Status (5)

Country Link
EP (1) EP2861364A2 (fr)
KR (1) KR20150004385A (fr)
CN (1) CN104379278A (fr)
DE (1) DE102012011992A1 (fr)
WO (1) WO2013186055A2 (fr)

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CN114406244A (zh) * 2022-01-11 2022-04-29 夏世林 一种分体式摩托车气缸体的制造工艺

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Also Published As

Publication number Publication date
WO2013186055A2 (fr) 2013-12-19
DE102012011992A1 (de) 2013-12-19
KR20150004385A (ko) 2015-01-12
CN104379278A (zh) 2015-02-25
WO2013186055A3 (fr) 2014-07-24

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