EP2964939B1 - Piston with anti-carbon deposit coating and method of construction thereof - Google Patents
Piston with anti-carbon deposit coating and method of construction thereof Download PDFInfo
- Publication number
- EP2964939B1 EP2964939B1 EP14710708.0A EP14710708A EP2964939B1 EP 2964939 B1 EP2964939 B1 EP 2964939B1 EP 14710708 A EP14710708 A EP 14710708A EP 2964939 B1 EP2964939 B1 EP 2964939B1
- Authority
- EP
- European Patent Office
- Prior art keywords
- piston
- cooling gallery
- crown
- combustion
- stick material
- 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.)
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- 238000000034 method Methods 0.000 title claims description 16
- 239000011248 coating agent Substances 0.000 title description 27
- 238000000576 coating method Methods 0.000 title description 27
- 229910052799 carbon Inorganic materials 0.000 title description 17
- 238000010276 construction Methods 0.000 title description 2
- 238000002485 combustion reaction Methods 0.000 claims description 66
- 239000000463 material Substances 0.000 claims description 66
- 238000001816 cooling Methods 0.000 claims description 62
- 239000000567 combustion gas Substances 0.000 claims description 5
- 229910017052 cobalt Inorganic materials 0.000 claims description 4
- 239000010941 cobalt Substances 0.000 claims description 4
- GUTLYIVDDKVIGB-UHFFFAOYSA-N cobalt atom Chemical compound [Co] GUTLYIVDDKVIGB-UHFFFAOYSA-N 0.000 claims description 4
- 238000005304 joining Methods 0.000 description 17
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 description 16
- 239000003921 oil Substances 0.000 description 14
- 238000003466 welding Methods 0.000 description 13
- 239000010410 layer Substances 0.000 description 7
- 238000009413 insulation Methods 0.000 description 5
- 230000001965 increasing effect Effects 0.000 description 3
- 238000005496 tempering Methods 0.000 description 3
- 229910000851 Alloy steel Inorganic materials 0.000 description 2
- 230000008901 benefit Effects 0.000 description 2
- 230000015572 biosynthetic process Effects 0.000 description 2
- 238000005219 brazing Methods 0.000 description 2
- 239000002800 charge carrier Substances 0.000 description 2
- 239000010724 circulating oil Substances 0.000 description 2
- 238000009792 diffusion process Methods 0.000 description 2
- 230000003292 diminished effect Effects 0.000 description 2
- 238000010894 electron beam technology Methods 0.000 description 2
- 239000000446 fuel Substances 0.000 description 2
- 239000007789 gas Substances 0.000 description 2
- 230000006698 induction Effects 0.000 description 2
- 238000005476 soldering Methods 0.000 description 2
- 239000007921 spray Substances 0.000 description 2
- 238000003756 stirring Methods 0.000 description 2
- 239000011247 coating layer Substances 0.000 description 1
- 239000000470 constituent Substances 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 230000002708 enhancing effect Effects 0.000 description 1
- 230000003628 erosive effect Effects 0.000 description 1
- 238000004372 laser cladding Methods 0.000 description 1
- 238000004519 manufacturing process Methods 0.000 description 1
- 239000000203 mixture Substances 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 239000010705 motor oil Substances 0.000 description 1
- 238000005240 physical vapour deposition Methods 0.000 description 1
- 238000007747 plating Methods 0.000 description 1
- 238000010301 surface-oxidation reaction Methods 0.000 description 1
- 238000007751 thermal spraying Methods 0.000 description 1
- 239000002699 waste material Substances 0.000 description 1
Images
Classifications
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- 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
- F02F3/00—Pistons
-
- 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
- F02F3/00—Pistons
- F02F3/10—Pistons having surface coverings
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- 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
- F05C2201/0463—Cobalt
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- 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
- F05C2253/00—Other material characteristics; Treatment of material
- F05C2253/12—Coating
Definitions
- This invention relates generally to internal combustion engines, and more particularly to pistons and their method of construction.
- the outer cooling galleries typically circulates about an upper land of the piston including a ring groove region while the inner cooling gallery is typically beneath an upper combustion surface of the piston head, commonly referred to as undercrown, which commonly includes a recessed combustion bowl.
- undercrown which commonly includes a recessed combustion bowl.
- both the ring belt region and the combustion surface benefit from cooling action of the circulated oil.
- the circulated oil begins to degrade and oxidize as a result of contacting the high temperature surfaces, and thus, carbon deposits form on the inner surfaces of the upper land and undercrown. As the carbon build-up continues, an insulation layer is formed on the respective surfaces.
- the cooling effects of the circulated oil are diminished, which in turn leads to surface oxidation and erosion, as well as over tempering of the upper land and combustion surface regions.
- the mechanical properties of the piston material are diminished, which can lead to crack formation, particularly as high stressed regions, such as a combustion bowl rim.
- a piston constructed in accordance with this invention overcomes the aforementioned disadvantages brought on by the formation of carbon build-up by reducing the tendency for oil deposits to accumulate surfaces contacted by cooling oil. As such, a piston constructed in accordance with this invention realizes enhanced running efficiencies, maintains the strength and durability of the base material throughout use and provides an enhanced useful operating life.
- US 2007 / 0113808 A1 and EP 2 096 290 A1 disclose pistons according to the preamble of claim 1.
- a piston for an internal combustion engine includes a piston body having an upper combustion surface configured for direct exposure to combustion gases within a cylinder bore with an undercrown surface located beneath the upper combustion surface.
- the piston body also includes a ring belt region configured for receipt of at least one piston ring adjacent the upper combustion surface with a cooling gallery configured radially inwardly and in substantial radial alignment with the ring belt region.
- the piston further includes a non-stick material bonded to at least one of the undercrown surface and at least a portion of the cooling gallery, wherein the non-stick material inhibits the build-up of carbon deposits thereon.
- the piston body includes an upper crown constructed of a first piece of material and a lower crown constructed from a second piece of material separate from the upper crown.
- the upper crown is fixed to the lower crown and the non-stick material is bonded to at least one of the upper crown and lower crown.
- the non-stick material is bonded to the upper crown and the lower crown is free of the non-stick material.
- both the cooling gallery and the undercrown surface have the non-stick material bonded thereto.
- a method of constructing a piston for an internal combustion engine includes the following: forming a piston body having an upper combustion surface configured for direct exposure to combustion gases within a cylinder bore and an undercrown surface beneath the upper combustion surface; forming a ring belt region configured for receipt of at least one piston ring adjacent the upper combustion surface; forming a cooling gallery radially inwardly and in substantial radial alignment with the ring belt region; and forming at least one of the undercrown surface and at least a portion of the cooling gallery from a non-stick material selected from the group consisting of pure cobalt, WC-17Co, Co-18Cr-30Mo, the non-stick material being resistant to the build-up of carbon deposits thereon.
- the method includes keeping the lower crown free of the non-stick material.
- the method includes bonding the non-stick coating material to the undercrown surface and at least a portion of the cooling gallery.
- Figures 1 and 2 illustrate a piston assembly, referred to hereafter simply as piston 10, constructed according to one presently preferred embodiment of the invention, for reciprocating movement in a cylinder bore or chamber of an internal combustion engine (not shown), such as light vehicle diesel, midrange diesel, heavy duty and large bore diesel engines, and gas engines, for example.
- the piston 10 has a piston body 12, shown as a single, monolithic piece of cast material or formed from either forged or billet materials, by way of example, extending along a central longitudinal axis 14 along which the piston 10 reciprocates in the cylinder bore.
- the body 12 is formed including an upper combustion wall having on one side an upper combustion surface 16 configured for direct exposure to combustion gases within a cylinder bore and on an opposite side an undercrown surface 18 located directly and axially beneath the upper combustion surface 16.
- the piston body 12 is also formed having a ring belt region 20 adjacent the upper combustion surface 16 wherein the ring belt region 20 is configured for receipt of at least one piston ring (not shown).
- the piston body 12 is formed including cooling gallery, shown as a closed or substantially closed cooling gallery 22, by way of example.
- the cooling gallery 22 is configured radially inwardly and in substantial radial alignment with the ring belt region 20.
- the piston 10 further includes a non-stick coating material 24 bonded to at least one of the undercrown surface 18 within a central gallery and at least a portion of the cooling gallery 22, wherein the non-stick coating material 24 resists the build-up of carbon deposits thereon.
- the non-stick coating 24 material can be applied via the following processes: plating, thermal spraying, PVD, laser cladding, by way of example and without limitation. Otherwise, according to an example which does not form part of the invention, if the piston or portions thereof are made of a steel alloy, the non-stick material can be added as a constituent of the composition of the steel alloy ( Figure 6 ).
- the build-up of an insulation layer including carbon deposits from circulating oil, is prevented from forming on the surfaces having the non-stick coating material 24, and thus, the oil circulated through the cooling gallery 22 and against the undercrown surface 18 is able to perform its cooling function, thereby enhancing the performance of the piston 10 and extending its useful life.
- the piston body 12 has an upper crown region 26 and a lower crown region 28.
- the lower crown region 28 provides a pair of pin bosses 30 depending from the upper crown region 26 to provide laterally spaced pin bores 32 coaxially aligned along a pin bore axis 34 that extends generally transverse to the central longitudinal axis 14.
- the pin bosses 30 are joined to laterally spaced skirt portions 36 via strut portions 38.
- the skirt portions 36 are diametrically spaced from one another across opposite sides the pin bore axis 34 and have convex outer surfaces contoured for cooperation within the cylinder bore to maintain the piston 10 in a desired orientation as it reciprocates through the cylinder bore.
- the upper combustion surface 16 is represented as having a recessed combustion bowl 40 to provide a desired gas flow with the cylinder bore. At least in part due to the combustion bowl 40, relatively thin regions of piston body material are formed between the combustion bowl 40, the cooling gallery 22 and the undercrown surface 18. As such, in use, these regions need to be properly cooled, such as via oil flowing through the cooling gallery 22 and against the undercrown surface 18 with a central gallery region between the pin bosses 30.
- the undercrown cooling could be provided by oil splashes, oriented cooling oil jets or via oil within the central gallery region.
- an outer wall 42 of the upper crown region 26 extends downwardly from the upper combustion surface 16.
- the outer wall 42 is formed having at least one, and shown as a plurality of annular ring groove 44 in the ring belt region 20 for receipt of corresponding piston rings (not shown), wherein the rings typically float freely within their respective ring groove 44.
- the annular wall extending between the cooling gallery 22 and the ring belt region 20 is relatively thin, and thus, also needs to be properly cooled during use.
- the non-stick coating material 24 is bonded to at least a portion of surface bounding the cooling gallery 22 and also to the undercrown surface 18.
- the non-stick coating material 24 is selected from the group consisting of: pure cobalt , WC-17Co, and Co-18Cr-30Mo.
- the non-stick coating material 24 is bonded about the entire surface bounding the annular cooling gallery 22, or only along the upper part of the cooling gallery 22, with the coating material 24 extending substantially along the length of the ring belt region 20 and also along an upwardly extending portion of the combustion bowl 40.
- the undercrown surface 18 is shown having a layer of the non-stick coating material 24 bonded thereto and extending completely therealong.
- carbon deposits are prevented from accumulating on the undercrown surface 18, thereby preventing an insulation layer of carbon deposits from forming that would otherwise inhibit the cooling effectiveness of the oil splashing against the undercrown surface 18.
- the material of the piston body 12 in this region is also prevented from becoming weakened via unintended tempering. Accordingly, the material of the upper combustion surface 16 retains its high strength and resistance to crack propagation.
- a piston 110 constructed in accordance with another aspect of the invention is shown in Figure 3 , wherein the same reference numerals, offset by a factor of 100, are used to identify like features discussed above.
- the piston 110 has a piston body 112 including an upper combustion surface 116 represented as having a combustion bowl 140 recessed therein and an undercrown surface 118 beneath the upper combustion surface 116.
- the piston body 112 also includes a ring belt region 120 adjacent the upper combustion surface 116 with a closed or substantially closed cooling gallery 122 configured radially inwardly and in substantial radial alignment with the ring belt region 120.
- a non-stick coating material 124 is shown as being bonded to at least one of the undercrown surface 118 and at least a portion of the cooling gallery 122, wherein the non-stick coating material 124 inhibits the build-up of carbon deposits thereon, as discussed above.
- the piston body 112 has an upper part, referred to as an upper crown region 126 and a lower part, referred to as a lower crown region 128 extending to a pair of pin bosses 130 having laterally spaced pin bores 132.
- the upper and lower crown regions 126, 128 are constructed from separate pieces of material and subsequently fixed to one another, such as via a welding or other joining process.
- a first weld joint 50 unites a portion of the separately made upper and lower crown regions 126, 128 of the piston 110.
- the first weld joint 50 extends through an upstanding wall of a combustion bowl 140 above an annular valley 52 of the combustion bowl 140.
- the first weld joint 50 is open to the combustion bowl 140 above the valley 52.
- a second weld joint 54 extends through an outer wall 142 in a ring belt region 120.
- the upper crown region 126 may thus include a pair of upper joining surfaces, including a radially inner, downwardly facing joining surface 56 and a radially outer, downwardly facing upper joining surface 57 of the ring belt region 120.
- the lower crown region 128 may thus include a pair of lower joining surfaces, including a radially inner, upwardly facing lower surface 58 and a radially outer, upwardly facing lower joining surface 59.
- the associated lower and upper joining surfaces 56, 57; 58, 59 may be united by a selected joining process, such as induction welding, friction welding, resistance welding, charge carrier rays, electron beam welding, laser welding, stir welding, brazing, soldering, hot or cold diffusion, etc.
- the upper crown region 126 provides an upper portion of the cooling gallery 122, having a generally U-shape in cross-section taken along a central longitudinal axis 114 of the piston 110.
- the lower crown region 128 provides a lower portion of the cooling gallery 122, having a generally U-shape in cross-section taken along the central longitudinal axis 114 and also the wall of the upper combustion surface 116 and undercrown surface 118.
- the non-stick coating material 124 can be bonded to the desired surfaces of the separate upper and lower parts 126, 128, including the undercrown surface 118 and/or one or both of the generally U-shaped surfaces bounding the cooling gallery 122, shown in Figure 3 as both generally U-shaped surfaces.
- the non-stick coating material 124 being bonded to both generally U-shaped surfaces, the entire or upper part of the cooling gallery 122 is coated and thus, the entire upstanding surfaces running along both the upper combustion surface and the ring belt region 120 are coated. Accordingly, carbon deposits are prevented from forming an insulation layer in these regions, thus allowing these regions to be properly cooled by circulating oil in the cooling gallery 122.
- a piston 210 constructed in accordance with another aspect of the invention is shown in Figure 4 , wherein the same reference numerals, offset by a factor of 200, are used to identify like features discussed above.
- the piston 210 has a piston body 212 including an upper combustion surface 216 represented as having a combustion bowl 240 recessed therein and an undercrown surface 218 beneath the upper combustion surface 216.
- the piston body 212 also includes a ring belt region 220 adjacent the upper combustion surface 216.
- the piston body 212 is configured similarly as the piston body 112 illustrated in Figure 3 , however, rather than being constructed from separate pieces of material, it is constructed as a single monolithic piece of material.
- the piston body 212 has an "open" cooling gallery 222 configured radially inwardly and in substantial radial alignment with the ring belt region 220.
- an "open means that the cooling gallery 222 is open along its lower portion, and thus, does not include a floor as in the previous embodiments.
- a non-stick coating material 224 is shown as being bonded to at least one of the undercrown surface 218 and the cooling gallery 222, shown as both, wherein the non-stick coating material 224 inhibits the build-up of carbon deposits thereon, as discussed above.
- the non-stick coating material 224 extends along the undercrown surface 218 and the surface bounding the cooling gallery 222 as a continuous, uninterrupted coating layer.
- the coating will be bonded preferentially along a gallery area perpendicular to the spray direction.
- a piston 310 constructed in accordance with another aspect of the invention is shown in Figure 5 , wherein the same reference numerals, offset by a factor of 300, are used to identify like features discussed above.
- the piston 310 has a piston body 312 including an upper combustion surface 316 represented as having a combustion bowl 340 recessed therein and an undercrown surface 318 beneath the upper combustion surface 316.
- the piston body 312 also includes a ring belt region 320 adjacent the upper combustion surface 316 with a closed or substantially closed cooling gallery 322 configured radially inwardly and in substantial radial alignment with the ring belt region 320.
- a non-stick coating material 324 is shown as being bonded to at least one of the undercrown surface 318 and at least a portion of the cooling gallery 322, wherein the non-stick coating material 324 inhibits the build-up of carbon deposits thereon, as discussed above.
- the piston body 312 as discussed for the piston body 112 of Figure 3 , has an upper part, referred to as an upper crown region 326 and a lower part, referred to as a lower crown region 328 extending to a pair of pin bosses 330 having laterally spaced pin bores 332.
- the upper and lower crown regions 326, 328 are constructed from separate pieces of material and subsequently fixed to one another.
- a first weld joint 350 unites a portion of the separately made upper and lower crown regions 326, 328 of the piston 310. However, unlike the piston 110, the first weld joint 350 does not extend through an upstanding wall of a combustion bowl 340 above an annular valley 352 of the combustion bowl 340, but rather, the first weld joint 350 is formed beneath the combustion bowl 340.
- the combustion bowl 340 is formed entirely of the material of the upper crown region 326, including the upstanding wall of the combustion bowl.
- a second weld joint 354 extends through an outer wall 342 in a ring belt region 320.
- the upper crown region 326 may thus include a pair of upper joining surfaces, including a radially inner, downwardly facing joining surface 356 extending below the combustion bowl 340 and a radially outer, downwardly facing upper joining surface 357 within the ring belt region 320.
- the lower crown region 328 may thus include a pair of lower joining surfaces, including a radially inner, upwardly facing lower surface 358 and a radially outer, upwardly facing lower joining surface 359.
- the associated lower and upper joining surfaces 356, 357; 358, 359 may be united by a selected joining process, such as induction welding, friction welding, resistance welding, charge carrier rays, electron beam welding, laser welding, stir welding, brazing, soldering, hot or cold diffusion, etc.
- the upper crown region 326 provides an upper portion of the cooling gallery 322, having a generally U-shape in cross-section taken along a central longitudinal axis 314 of the piston 310.
- the lower crown region 328 provides a lower portion of the cooling gallery 322, having a generally U-shape in cross-section taken along the central longitudinal axis 314. Accordingly, prior to joining the upper crown region 326 to the lower crown region 328, the non-stick coating material 324 can be bonded to the desired surfaces of the separate upper and lower parts 326, 328, including the undercrown surface 318 and/or one or both of the generally U-shaped surfaces bounding the cooling gallery 322, shown in Figure 5 as only the generally U-shaped surface bounding the upper portion of the cooling gallery 322.
- the non-stick coating material 324 can be bonded to the desired surfaces on the upper part 326, while the lower part 328 can remain uncoated.
- the non-stick coating material 324 is applied as needed, without waste, to the areas desired.
Description
- This invention relates generally to internal combustion engines, and more particularly to pistons and their method of construction.
- Engine manufacturers are encountering increasing demands to improve engine efficiencies and performance, including, but not limited to, improving fuel economy, improving fuel combustion, reducing oil consumption, and increasing the exhaust temperature for subsequent use of the heat within the vehicle. In order to achieve these goals, the engine running temperature in the combustion chamber needs to be increased. However, while desirable to increase the temperature within the combustion chamber, it remains necessary to maintain the piston at a workable temperature. As such, it is known to incorporate outer and inner cooling galleries, both open and closed, within the piston head through which engine oil is circulated to reduce the operating temperature of the piston head. The outer cooling galleries typically circulates about an upper land of the piston including a ring groove region while the inner cooling gallery is typically beneath an upper combustion surface of the piston head, commonly referred to as undercrown, which commonly includes a recessed combustion bowl. As such, both the ring belt region and the combustion surface benefit from cooling action of the circulated oil. However, over time the circulated oil begins to degrade and oxidize as a result of contacting the high temperature surfaces, and thus, carbon deposits form on the inner surfaces of the upper land and undercrown. As the carbon build-up continues, an insulation layer is formed on the respective surfaces. As such, the cooling effects of the circulated oil are diminished, which in turn leads to surface oxidation and erosion, as well as over tempering of the upper land and combustion surface regions. As such, the mechanical properties of the piston material are diminished, which can lead to crack formation, particularly as high stressed regions, such as a combustion bowl rim.
- A piston constructed in accordance with this invention overcomes the aforementioned disadvantages brought on by the formation of carbon build-up by reducing the tendency for oil deposits to accumulate surfaces contacted by cooling oil. As such, a piston constructed in accordance with this invention realizes enhanced running efficiencies, maintains the strength and durability of the base material throughout use and provides an enhanced useful operating life.
US 2007 / 0113808 A1 andEP 2 096 290 A1 disclose pistons according to the preamble of claim 1. - The invention is defined by the independent claims.
- In accordance with one aspect of the invention, a piston for an internal combustion engine is provided. The piston includes a piston body having an upper combustion surface configured for direct exposure to combustion gases within a cylinder bore with an undercrown surface located beneath the upper combustion surface. The piston body also includes a ring belt region configured for receipt of at least one piston ring adjacent the upper combustion surface with a cooling gallery configured radially inwardly and in substantial radial alignment with the ring belt region. The piston further includes a non-stick material bonded to at least one of the undercrown surface and at least a portion of the cooling gallery, wherein the non-stick material inhibits the build-up of carbon deposits thereon.
- In accordance with another aspect of the invention, the piston body includes an upper crown constructed of a first piece of material and a lower crown constructed from a second piece of material separate from the upper crown. The upper crown is fixed to the lower crown and the non-stick material is bonded to at least one of the upper crown and lower crown.
- In accordance with another aspect of the invention, the non-stick material is bonded to the upper crown and the lower crown is free of the non-stick material.
- In accordance with another aspect of the invention, both the cooling gallery and the undercrown surface have the non-stick material bonded thereto.
- In accordance with yet another aspect of the invention, a method of constructing a piston for an internal combustion engine is provided. The method includes the following: forming a piston body having an upper combustion surface configured for direct exposure to combustion gases within a cylinder bore and an undercrown surface beneath the upper combustion surface; forming a ring belt region configured for receipt of at least one piston ring adjacent the upper combustion surface; forming a cooling gallery radially inwardly and in substantial radial alignment with the ring belt region; and forming at least one of the undercrown surface and at least a portion of the cooling gallery from a non-stick material selected from the group consisting of pure cobalt, WC-17Co, Co-18Cr-30Mo, the non-stick material being resistant to the build-up of carbon deposits thereon.
- In accordance with another aspect of the invention, the method includes keeping the lower crown free of the non-stick material.
- In accordance with another aspect of the invention, the method includes bonding the non-stick coating material to the undercrown surface and at least a portion of the cooling gallery.
- These and other aspects, features and advantages of the invention will become more readily appreciated when considered in connection with the following detailed description of presently preferred embodiments and best mode, appended claims and accompanying drawings, in which:
-
Figure 1 is a cross-sectional view taken generally along a pin bore axis of a piston constructed in accordance with one aspect of the invention; -
Figure 2 is a cross-sectional view taken generally transversely to the pin bore of the piston ofFigure 1 ; -
Figure 3 is a cross-sectional view taken generally transversely to a pin bore of a piston constructed in accordance with another aspect of the invention; -
Figure 4 is a cross-sectional view taken generally transversely to a pin bore of a piston constructed in accordance with yet another aspect of the invention; -
Figure 5 is a cross-sectional view taken generally transversely to a pin bore of a piston constructed in accordance with yet another aspect of the invention; and -
Figure 6 is a cross-sectional view taken generally along a pin bore axis of a piston, not according to the present invention. - Referring in more detail to the drawings,
Figures 1 and 2 illustrate a piston assembly, referred to hereafter simply aspiston 10, constructed according to one presently preferred embodiment of the invention, for reciprocating movement in a cylinder bore or chamber of an internal combustion engine (not shown), such as light vehicle diesel, midrange diesel, heavy duty and large bore diesel engines, and gas engines, for example. Thepiston 10 has apiston body 12, shown as a single, monolithic piece of cast material or formed from either forged or billet materials, by way of example, extending along a centrallongitudinal axis 14 along which thepiston 10 reciprocates in the cylinder bore. Thebody 12 is formed including an upper combustion wall having on one side anupper combustion surface 16 configured for direct exposure to combustion gases within a cylinder bore and on an opposite side anundercrown surface 18 located directly and axially beneath theupper combustion surface 16. Thepiston body 12 is also formed having aring belt region 20 adjacent theupper combustion surface 16 wherein thering belt region 20 is configured for receipt of at least one piston ring (not shown). Further, thepiston body 12 is formed including cooling gallery, shown as a closed or substantially closedcooling gallery 22, by way of example. Thecooling gallery 22 is configured radially inwardly and in substantial radial alignment with thering belt region 20. Thepiston 10 further includes anon-stick coating material 24 bonded to at least one of theundercrown surface 18 within a central gallery and at least a portion of thecooling gallery 22, wherein thenon-stick coating material 24 resists the build-up of carbon deposits thereon. Thenon-stick coating 24 material can be applied via the following processes: plating, thermal spraying, PVD, laser cladding, by way of example and without limitation. Otherwise, according to an example which does not form part of the invention, if the piston or portions thereof are made of a steel alloy, the non-stick material can be added as a constituent of the composition of the steel alloy (Figure 6 ). As such, the build-up of an insulation layer, including carbon deposits from circulating oil, is prevented from forming on the surfaces having thenon-stick coating material 24, and thus, the oil circulated through thecooling gallery 22 and against theundercrown surface 18 is able to perform its cooling function, thereby enhancing the performance of thepiston 10 and extending its useful life. - The
piston body 12 has anupper crown region 26 and alower crown region 28. Thelower crown region 28 provides a pair ofpin bosses 30 depending from theupper crown region 26 to provide laterally spacedpin bores 32 coaxially aligned along apin bore axis 34 that extends generally transverse to the centrallongitudinal axis 14. Thepin bosses 30 are joined to laterally spacedskirt portions 36 viastrut portions 38. Theskirt portions 36 are diametrically spaced from one another across opposite sides thepin bore axis 34 and have convex outer surfaces contoured for cooperation within the cylinder bore to maintain thepiston 10 in a desired orientation as it reciprocates through the cylinder bore. - The
upper combustion surface 16 is represented as having arecessed combustion bowl 40 to provide a desired gas flow with the cylinder bore. At least in part due to thecombustion bowl 40, relatively thin regions of piston body material are formed between thecombustion bowl 40, thecooling gallery 22 and theundercrown surface 18. As such, in use, these regions need to be properly cooled, such as via oil flowing through thecooling gallery 22 and against theundercrown surface 18 with a central gallery region between thepin bosses 30. The undercrown cooling could be provided by oil splashes, oriented cooling oil jets or via oil within the central gallery region. Further, anouter wall 42 of theupper crown region 26 extends downwardly from theupper combustion surface 16. Theouter wall 42 is formed having at least one, and shown as a plurality ofannular ring groove 44 in thering belt region 20 for receipt of corresponding piston rings (not shown), wherein the rings typically float freely within theirrespective ring groove 44. As with the aforementioned relatively thin regions, the annular wall extending between thecooling gallery 22 and thering belt region 20 is relatively thin, and thus, also needs to be properly cooled during use. - To facilitate proper cooling of the
upper combustion surface 16, including thecombustion bowl 40, and thering belt region 20 during use over an extended useful life of thepiston 10, thenon-stick coating material 24 is bonded to at least a portion of surface bounding thecooling gallery 22 and also to theundercrown surface 18. Thenon-stick coating material 24 is selected from the group consisting of: pure cobalt , WC-17Co, and Co-18Cr-30Mo. In the embodiment shown inFigures 1 and 2 , thenon-stick coating material 24 is bonded about the entire surface bounding theannular cooling gallery 22, or only along the upper part of thecooling gallery 22, with thecoating material 24 extending substantially along the length of thering belt region 20 and also along an upwardly extending portion of thecombustion bowl 40. As such, carbon deposits are prevented from accumulating in these regions, thereby preventing an insulation layer including carbon deposits from forming that would otherwise inhibit the cooling effectiveness of the oil circulating through the coolinggallery 22. Thus, by allowing proper cooling to take place via circulated oil, the material of thepiston body 12 throughout the region cooled is prevented from becoming weakened via unintended tempering. Accordingly, the material of thepiston body 12 retains its high strength and resistance to crack propagation. Further, the piston rings andring grooves 44 are adequately cooled to prevent carbon build-up thereon, thereby allowing the rings to float and function as intended without becoming seized in theirrespective ring grooves 44. - In addition to the
cooling gallery 22 having a layer of thenon-stick coating material 24 bonded thereto, theundercrown surface 18 is shown having a layer of thenon-stick coating material 24 bonded thereto and extending completely therealong. As such, carbon deposits are prevented from accumulating on theundercrown surface 18, thereby preventing an insulation layer of carbon deposits from forming that would otherwise inhibit the cooling effectiveness of the oil splashing against theundercrown surface 18. Thus, by allowing proper cooling of theupper combustion surface 16, including theentire combustion bowl 40, the material of thepiston body 12 in this region is also prevented from becoming weakened via unintended tempering. Accordingly, the material of theupper combustion surface 16 retains its high strength and resistance to crack propagation. - A
piston 110 constructed in accordance with another aspect of the invention is shown inFigure 3 , wherein the same reference numerals, offset by a factor of 100, are used to identify like features discussed above. Thepiston 110 has apiston body 112 including anupper combustion surface 116 represented as having a combustion bowl 140 recessed therein and anundercrown surface 118 beneath theupper combustion surface 116. Thepiston body 112 also includes aring belt region 120 adjacent theupper combustion surface 116 with a closed or substantially closedcooling gallery 122 configured radially inwardly and in substantial radial alignment with thering belt region 120. A non-stick coating material 124 is shown as being bonded to at least one of theundercrown surface 118 and at least a portion of thecooling gallery 122, wherein the non-stick coating material 124 inhibits the build-up of carbon deposits thereon, as discussed above. - The
piston body 112 has an upper part, referred to as anupper crown region 126 and a lower part, referred to as alower crown region 128 extending to a pair ofpin bosses 130 having laterally spaced pin bores 132. Unlike thepiston 10 discussed above, the upper andlower crown regions - A first weld joint 50 unites a portion of the separately made upper and
lower crown regions piston 110. The first weld joint 50 extends through an upstanding wall of a combustion bowl 140 above anannular valley 52 of the combustion bowl 140. Thus, the first weld joint 50 is open to the combustion bowl 140 above thevalley 52. In addition to the first weld joint 50 extending through the wall of the combustion bowl 140, a second weld joint 54 extends through anouter wall 142 in aring belt region 120. Theupper crown region 126 may thus include a pair of upper joining surfaces, including a radially inner, downwardly facing joiningsurface 56 and a radially outer, downwardly facing upper joiningsurface 57 of thering belt region 120. Meanwhile, thelower crown region 128 may thus include a pair of lower joining surfaces, including a radially inner, upwardly facinglower surface 58 and a radially outer, upwardly facing lower joiningsurface 59. The associated lower and upper joiningsurfaces - The
upper crown region 126 provides an upper portion of thecooling gallery 122, having a generally U-shape in cross-section taken along a centrallongitudinal axis 114 of thepiston 110. Thelower crown region 128 provides a lower portion of thecooling gallery 122, having a generally U-shape in cross-section taken along the centrallongitudinal axis 114 and also the wall of theupper combustion surface 116 andundercrown surface 118. Accordingly, prior to joining theupper crown region 126 to thelower crown region 128, the non-stick coating material 124 can be bonded to the desired surfaces of the separate upper andlower parts undercrown surface 118 and/or one or both of the generally U-shaped surfaces bounding thecooling gallery 122, shown inFigure 3 as both generally U-shaped surfaces. As such, with the non-stick coating material 124 being bonded to both generally U-shaped surfaces, the entire or upper part of thecooling gallery 122 is coated and thus, the entire upstanding surfaces running along both the upper combustion surface and thering belt region 120 are coated. Accordingly, carbon deposits are prevented from forming an insulation layer in these regions, thus allowing these regions to be properly cooled by circulating oil in thecooling gallery 122. - A
piston 210 constructed in accordance with another aspect of the invention is shown inFigure 4 , wherein the same reference numerals, offset by a factor of 200, are used to identify like features discussed above. Thepiston 210 has apiston body 212 including anupper combustion surface 216 represented as having acombustion bowl 240 recessed therein and anundercrown surface 218 beneath theupper combustion surface 216. Thepiston body 212 also includes aring belt region 220 adjacent theupper combustion surface 216. Overall, thepiston body 212 is configured similarly as thepiston body 112 illustrated inFigure 3 , however, rather than being constructed from separate pieces of material, it is constructed as a single monolithic piece of material. Further, rather than having a closed or substantially closed cooling gallery, thepiston body 212 has an "open" coolinggallery 222 configured radially inwardly and in substantial radial alignment with thering belt region 220. By being referred to as an "open means that thecooling gallery 222 is open along its lower portion, and thus, does not include a floor as in the previous embodiments. Anon-stick coating material 224 is shown as being bonded to at least one of theundercrown surface 218 and thecooling gallery 222, shown as both, wherein thenon-stick coating material 224 inhibits the build-up of carbon deposits thereon, as discussed above. As shown, thenon-stick coating material 224 extends along theundercrown surface 218 and the surface bounding thecooling gallery 222 as a continuous, uninterrupted coating layer. In case the coating is applied via a thermal spray method, the coating will be bonded preferentially along a gallery area perpendicular to the spray direction. - A
piston 310 constructed in accordance with another aspect of the invention is shown inFigure 5 , wherein the same reference numerals, offset by a factor of 300, are used to identify like features discussed above. Thepiston 310 has apiston body 312 including anupper combustion surface 316 represented as having acombustion bowl 340 recessed therein and anundercrown surface 318 beneath theupper combustion surface 316. Thepiston body 312 also includes aring belt region 320 adjacent theupper combustion surface 316 with a closed or substantially closedcooling gallery 322 configured radially inwardly and in substantial radial alignment with thering belt region 320. Anon-stick coating material 324 is shown as being bonded to at least one of theundercrown surface 318 and at least a portion of thecooling gallery 322, wherein thenon-stick coating material 324 inhibits the build-up of carbon deposits thereon, as discussed above. - The
piston body 312, as discussed for thepiston body 112 ofFigure 3 , has an upper part, referred to as anupper crown region 326 and a lower part, referred to as alower crown region 328 extending to a pair ofpin bosses 330 having laterally spaced pin bores 332. The upper andlower crown regions - A first weld joint 350 unites a portion of the separately made upper and
lower crown regions piston 310. However, unlike thepiston 110, the first weld joint 350 does not extend through an upstanding wall of acombustion bowl 340 above anannular valley 352 of thecombustion bowl 340, but rather, the first weld joint 350 is formed beneath thecombustion bowl 340. Thecombustion bowl 340 is formed entirely of the material of theupper crown region 326, including the upstanding wall of the combustion bowl. In addition to the first weld joint 350, a second weld joint 354 extends through anouter wall 342 in aring belt region 320. Theupper crown region 326 may thus include a pair of upper joining surfaces, including a radially inner, downwardly facing joiningsurface 356 extending below thecombustion bowl 340 and a radially outer, downwardly facing upper joiningsurface 357 within thering belt region 320. Meanwhile, thelower crown region 328 may thus include a pair of lower joining surfaces, including a radially inner, upwardly facinglower surface 358 and a radially outer, upwardly facing lower joiningsurface 359. The associated lower and upper joiningsurfaces - The
upper crown region 326 provides an upper portion of thecooling gallery 322, having a generally U-shape in cross-section taken along a central longitudinal axis 314 of thepiston 310. Thelower crown region 328 provides a lower portion of thecooling gallery 322, having a generally U-shape in cross-section taken along the central longitudinal axis 314. Accordingly, prior to joining theupper crown region 326 to thelower crown region 328, thenon-stick coating material 324 can be bonded to the desired surfaces of the separate upper andlower parts undercrown surface 318 and/or one or both of the generally U-shaped surfaces bounding thecooling gallery 322, shown inFigure 5 as only the generally U-shaped surface bounding the upper portion of thecooling gallery 322. As such, only the upper portion of thecooling gallery 322, which includes a portion extending along thecombustion bowl 340, while the lower portion of thecooling gallery 322 provided by thelower part 328 remains free from thecoating material 324. Accordingly, in manufacture, thenon-stick coating material 324 can be bonded to the desired surfaces on theupper part 326, while thelower part 328 can remain uncoated. Thus, thenon-stick coating material 324 is applied as needed, without waste, to the areas desired. - Obviously, many modifications and variations of the present invention are possible in light of the above teachings. It is, therefore, to be understood that within the scope of the appended claims, the invention may be practiced otherwise than as specifically described.
Claims (12)
- A piston (10) for an internal combustion engine, comprising:a piston body (12) having an upper combustion surface (16) configured for direct exposure to combustion gases within a cylinder bore with an undercrown surface (18) beneath said upper combustion surface (16) and having a ring belt region (20) configured for receipt of at least one piston ring adjacent said upper combustion surface (16) with a cooling gallery (22) configured radially inwardly from said ring belt region (20) and in substantial radial alignment with said ring belt region (20); anda non-stick material (24) bonded to at least one of said undercrown surface (18) and at least a portion of said cooling gallery (22), characterized by said non-stick material (24) being selected from the group consisting of: pure cobalt, WC-17Co, and Co-18Cr-30Mo.
- The piston (10) of claim 1 wherein said non-stick material (24) is bonded to said undercrown surface (18) and at least a portion of said cooling gallery (22).
- The piston (10) of one of the preceding claims wherein said piston body (12) is constructed as a monolithic piece of material.
- The piston of claim 3 wherein said cooling gallery (22) is a closed gallery.
- The piston (110) of claim 1 wherein said piston body (112) includes an upper crown (126) constructed of a first piece of material and a lower crown (128) constructed from a second piece of material separate from said upper crown (126), said upper crown (126) being fixed to said lower crown (128) and said non-stick material (124) being bonded to at least one of said upper crown and said lower crown.
- The piston of claim 5 wherein said lower crown (328) is free of said non-stick material (324).
- The piston of claim 6 wherein said non-stick material (324) is bonded to said undercrown surface and at least a portion of said cooling gallery (322).
- A method of constructing a piston (10) for an internal combustion engine, comprising:forming a piston body (12) having an upper combustion surface (16) configured for direct exposure to combustion gases within a cylinder bore and an undercrown surface (18) beneath the upper combustion surface;forming a ring belt region (20) configured for receipt of at least one piston ring adjacent the upper combustion surface (16);forming a cooling gallery (22) radially inwardly and in substantial radial alignment with the ring belt region (20); andforming at least one of the undercrown surface (18) and at least a portion of the cooling gallery (22) from a non-stick material (24) such that the non-stick material (24) is bonded to at least one of the undercrown surface (18) and at least a portion of the cooling gallery (22), wherein the non-stick material (24) is selected from the group consisting of: pure cobalt, WC-17Co, and Co-18Cr-30Mo,
- The method of claim 8 further including forming the piston body (12) as a monolithic piece of material.
- The method of claim 8 further including forming the piston body (112) having an upper crown (126) and a lower crown (128) constructed from separate pieces of material separate and fixing the upper crown (126) to the lower crown (128).
- The method of claim 10 further including keeping the lower crown (328) free of the non-stick material (324).
- The method of claim 11 further including bonding the non-stick material (324) to the undercrown surface (318) and at least a portion of the cooling gallery (322).
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US13/786,156 US9163579B2 (en) | 2011-11-28 | 2013-03-05 | Piston with anti-carbon deposit coating and method of construction thereof |
PCT/US2014/018573 WO2014137690A1 (en) | 2013-03-05 | 2014-02-26 | Piston with anti-carbon deposit coating and method of construction thereof |
Publications (2)
Publication Number | Publication Date |
---|---|
EP2964939A1 EP2964939A1 (en) | 2016-01-13 |
EP2964939B1 true EP2964939B1 (en) | 2021-11-17 |
Family
ID=50288288
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
EP14710708.0A Active EP2964939B1 (en) | 2013-03-05 | 2014-02-26 | Piston with anti-carbon deposit coating and method of construction thereof |
Country Status (5)
Country | Link |
---|---|
EP (1) | EP2964939B1 (en) |
JP (1) | JP6356704B2 (en) |
KR (1) | KR20150121239A (en) |
CN (1) | CN105190000B (en) |
WO (1) | WO2014137690A1 (en) |
Families Citing this family (3)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
EP3262209B1 (en) * | 2015-02-24 | 2022-01-26 | Oerlikon Surface Solutions AG, Pfäffikon | Method for coating a piston |
BR112017025644A2 (en) * | 2015-06-12 | 2018-09-11 | Mahle International Gmbh | method for coating a surface of a closed piston cooling channel to an internal combustion engine and piston which may be produced by said method |
DE102018100336A1 (en) * | 2018-01-09 | 2019-07-11 | Man Truck & Bus Ag | Piston for an internal combustion engine |
Citations (1)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US20060191508A1 (en) * | 2003-03-31 | 2006-08-31 | Koki Otsuka | Internal engine piston and its production method |
Family Cites Families (12)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US1876917A (en) * | 1929-08-10 | 1932-09-13 | Siemens Ag | Piston for internal combustion engines |
JPS5943470Y2 (en) * | 1980-02-28 | 1984-12-24 | 三菱電機株式会社 | internal combustion engine |
JP3149066B2 (en) * | 1991-04-19 | 2001-03-26 | ヤマハ発動機株式会社 | Piston for internal combustion engine |
GB2332448B (en) * | 1997-12-20 | 2002-06-26 | Ae Goetze Automotive Ltd | Aluminium alloy |
FR2848129B1 (en) * | 2002-12-05 | 2006-01-27 | Ascometal Sa | METHOD FOR MANUFACTURING A PISTON FOR AN EXPLOSION ENGINE, AND A PISTON THUS OBTAINED |
JPWO2005066481A1 (en) * | 2004-01-07 | 2007-07-26 | 株式会社小松製作所 | Piston for internal combustion engine |
US7458358B2 (en) * | 2006-05-10 | 2008-12-02 | Federal Mogul World Wide, Inc. | Thermal oxidation protective surface for steel pistons |
EP2096290B1 (en) * | 2008-02-29 | 2014-06-18 | Caterpillar Motoren GmbH & Co. KG | Engine piston with cooling chamber having a non-stick coating |
CN101629295A (en) * | 2009-08-05 | 2010-01-20 | 中国人民解放军第五七一九工厂 | Surface treating method of anti-carbon deposition for fuel nozzle |
BRPI0905186A2 (en) * | 2009-12-21 | 2011-08-09 | Mahle Metal Leve Sa | piston ring |
JP5603736B2 (en) * | 2010-10-27 | 2014-10-08 | 菊水化学工業株式会社 | Single cell for solid oxide fuel cell |
CN202531299U (en) * | 2012-03-28 | 2012-11-14 | 江苏兄弟活塞有限公司 | Aluminium piston for internal combustion engine capable of preventing carbon deposition |
-
2014
- 2014-02-26 WO PCT/US2014/018573 patent/WO2014137690A1/en active Application Filing
- 2014-02-26 CN CN201480025217.6A patent/CN105190000B/en not_active Expired - Fee Related
- 2014-02-26 KR KR1020157027530A patent/KR20150121239A/en active IP Right Grant
- 2014-02-26 JP JP2015561396A patent/JP6356704B2/en not_active Expired - Fee Related
- 2014-02-26 EP EP14710708.0A patent/EP2964939B1/en active Active
Patent Citations (1)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US20060191508A1 (en) * | 2003-03-31 | 2006-08-31 | Koki Otsuka | Internal engine piston and its production method |
Also Published As
Publication number | Publication date |
---|---|
EP2964939A1 (en) | 2016-01-13 |
JP2016509160A (en) | 2016-03-24 |
KR20150121239A (en) | 2015-10-28 |
JP6356704B2 (en) | 2018-07-11 |
CN105190000A (en) | 2015-12-23 |
CN105190000B (en) | 2018-11-20 |
WO2014137690A1 (en) | 2014-09-12 |
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