EP3325685B1 - Method for coating a cylinder barrel of a cylinder crankcase, cylinder crankcase with a coated cylinder barrel and engine - Google Patents

Method for coating a cylinder barrel of a cylinder crankcase, cylinder crankcase with a coated cylinder barrel and engine Download PDF

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Publication number
EP3325685B1
EP3325685B1 EP16730300.7A EP16730300A EP3325685B1 EP 3325685 B1 EP3325685 B1 EP 3325685B1 EP 16730300 A EP16730300 A EP 16730300A EP 3325685 B1 EP3325685 B1 EP 3325685B1
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EP
European Patent Office
Prior art keywords
base material
cylinder
layer
coating
bonding agent
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EP16730300.7A
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German (de)
French (fr)
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EP3325685A1 (en
Inventor
Klaus Stefan Klimek
Stefan Richter
Jürg WIPF
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Volkswagen AG
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Volkswagen AG
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Publication of EP3325685A1 publication Critical patent/EP3325685A1/en
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    • C—CHEMISTRY; METALLURGY
    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C28/00—Coating for obtaining at least two superposed coatings either by methods not provided for in a single one of groups C23C2/00 - C23C26/00 or by combinations of methods provided for in subclasses C23C and C25C or C25D
    • C23C28/02—Coating for obtaining at least two superposed coatings either by methods not provided for in a single one of groups C23C2/00 - C23C26/00 or by combinations of methods provided for in subclasses C23C and C25C or C25D only coatings only including layers of metallic material
    • C23C28/021—Coating for obtaining at least two superposed coatings either by methods not provided for in a single one of groups C23C2/00 - C23C26/00 or by combinations of methods provided for in subclasses C23C and C25C or C25D only coatings only including layers of metallic material including at least one metal alloy layer
    • C—CHEMISTRY; METALLURGY
    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
    • C23C4/04—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge characterised by the coating material
    • C23C4/06—Metallic material
    • C23C4/08—Metallic material containing only metal elements
    • C—CHEMISTRY; METALLURGY
    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
    • C23C4/04—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge characterised by the coating material
    • C23C4/06—Metallic material
    • 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 
    • F02F1/004—Cylinder liners
    • 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 
    • F02F1/18—Other cylinders
    • F02F1/20—Other cylinders characterised by constructional features providing for lubrication

Definitions

  • the invention relates to a method for coating a cylinder liner of a cylinder crankcase, a cylinder crankcase and an engine.
  • thermal spraying processes are often used to coat workpieces, such as plasma spraying; High speed flame spraying (HVOF), arc spraying and arc wire spraying.
  • layers are produced on a workpiece, the workpiece being, for example, metallic and the coating being metallic, ceramic or a mixture of the two.
  • the coating often comprises several individual layers, which are arranged one above the other and generally have different functionalities.
  • Thermal protective layers TBC
  • corrosion protection layers corrosion protection layers
  • erosion protection layers or sliding layers, which simplify the sliding together of counter-rotating bodies.
  • An application example is the coating of cylinder running surfaces in internal combustion engines with layers that have good lubricating and friction properties, which improves the running properties of the piston in the cylinder.
  • cylinder crankcases In vehicle construction and in particular in the production of cylinder crankcases (ZKG), lightweight construction is increasingly used.
  • aluminum cylinder crankcases are used, which have a coating in the area of the cylinder race.
  • the effect of the coating is, in addition to increasing the robustness of the raceway, a significantly reduced friction in the area of the piston group and associated reduction in CO 2 emissions, as well as positive effects against corrosive media.
  • Common thermal coating processes are powder plasma spraying, wire spraying processes such as plasma transfer wire arc (PTWA) and arc wire spraying (LDS) or high-speed flame spraying.
  • PTWA plasma transfer wire arc
  • LDS arc wire spraying
  • a thermal composite spray powder for thermal spraying of cylinder inner walls which comprises aluminum and a metal based on iron, namely cast iron or an iron-molybdenum alloy, as well as an organic binder.
  • US 2, 588,422 A discloses the manufacture of an aluminum cylinder block, the holes first being coated with molybdenum using a wire spray process and subsequently with a hard metal, such as steel.
  • a roughening process is required to clamp the coating in the surface.
  • the roughening process is carried out by blasting processes using corundum or water (medium-pressure / high-pressure water jets), laser beam roughening or roughening with a geometrically defined cutting edge.
  • corundum or water medium-pressure / high-pressure water jets
  • laser beam roughening or roughening with a geometrically defined cutting edge.
  • the methods described have the disadvantage that the blasting medium has to be prepared in a complex manner, and furthermore the processes have to be monitored by additional and extensive analysis methods and large amounts of dusts, chips and sludges have to be removed and disposed of. Furthermore, large investments have to be made to install these roughening processes.
  • Another disadvantage is that the emulsion rinsing of the cutting edges used in mechanical roughening is often not effective enough, so that chips remain in the roughening profile again and again and negatively influence the layer structure and the layer quality in the coating process.
  • large investments have to be made to install these roughening processes.
  • the invention is based on the object of providing a method for coating a metallic workpiece, namely a cylinder track of a cylinder crankcase, in which a pretreatment and in particular roughening of the surface are unnecessary.
  • a first aspect of the invention relates to a method for coating a cylinder liner of a cylinder crankcase consisting of gray cast iron or an aluminum-containing light metal alloy, comprising in a step (a) the provision of a powdery base material, the base material being iron or an iron alloy, and a powdery adhesion promoter .
  • the coupling agent comprises a mixture of 20 to 80% by weight of molybdenum; 20 to 80% by weight of an aluminum-containing alloy which is selected from a nickel-aluminum alloy NiAl, in particular Ni (95%) Al (5%), a copper-aluminum alloy CuAl, in particular Cu (90%) Al (10 %), a cobalt-aluminum alloy, a magnesium-cobalt-aluminum alloy, a silicon-aluminum alloy, a silver-aluminum alloy and an aluminum-bronze; and optionally 0.2 to 5% by weight of boron, the molybdenum, the aluminum-containing alloy and boron adding up to 100% by weight.
  • an aluminum-containing alloy which is selected from a nickel-aluminum alloy NiAl, in particular Ni (95%) Al (5%), a copper-aluminum alloy CuAl, in particular Cu (90%) Al (10 %), a cobalt-aluminum alloy, a magnesium-cobalt-a
  • the method according to the invention comprises applying the base material and the adhesion promoter to the cylinder race of the cylinder crankcase by means of a thermal coating method in step (b), wherein either a layer of a powder mixture of the adhesion promoter and the base material on which the cylinder race is arranged or a first one Layer comprising the adhesion promoter arranged on the cylinder track and then a second layer comprising the base material is arranged on the first layer.
  • Thermal coating processes are powder plasma spraying, wire spraying processes such as plasma transfer wire arc (PTWA) and arc wire spraying (LDS) or high-speed flame spraying.
  • PTWA plasma transfer wire arc
  • LDS arc wire spraying
  • adhesion promoters mentioned ensure very good adhesion by exothermic reaction of the components with one another, in particular in connection with molybdenum, Ni (95%) Al (5%) in particular having proven suitable.
  • the layer does not self-grow or self-weld during the coating, and therefore no intermetallic bonds are produced.
  • a process step for pretreatment which precedes a coating of the workpiece, is not necessary and can be saved. This saving leads to economic, in particular financial advantages, since the process time is reduced overall. If the pretreatment involves roughening the material, there is also no need to dispose of the materials used in the roughening process.
  • an increase in the quality of the workpiece is additionally achieved, since errors on the workpiece surface, which can occur as a result of the pretreatment, in particular the roughening of the surface, are completely avoided.
  • finely spindleed surfaces can also be coated without loss of quality.
  • the coating produced with the method according to the invention serves as a protective layer for a cylinder track of a cylinder crankcase.
  • the protective layer preferably increases the friction resistance.
  • the properties of the protective layer are largely determined by the base material.
  • the adhesion promoter is either arranged together with the base material on the metallic workpiece surface (cylinder raceway) and is then present together with the base material in a mixed layer on the workpiece surface, so that an adhesive base integrated in the protective layer is formed.
  • the method according to the invention provides for the adhesion promoter to be arranged in a separate layer without base material as a primer on the workpiece surface and then for a protective layer to be arranged on the primer, which preferably has only the base material, but at least not the adhesion promoter.
  • the adhesion promoter and the base powder are present as a physical mixture, i.e. they do not form any chemical compounds or alloys.
  • adhesion promoter The separation of adhesion promoter and base material in two layers offers several advantages. On the one hand, the effect of the adhesion promoter can be increased and thus the adhesive tensile values of the coating on the workpiece surface can be improved, on the other hand the adhesion promoter does not come with the separate application of the individual layers Surrounding the workpiece. Interaction of the adhesion promoter with the surroundings of the workpiece can thus be avoided.
  • All of the layers mentioned are preferably coated using the same thermal coating method.
  • the disadvantages of an additional coating step are thus negligible, especially when special precautions are taken, such as the use of a plasma torch with a double powder conveyor for powder supply, in order to keep the additional expenditure of an additional coating step as low as possible.
  • special precautions such as the use of a plasma torch with a double powder conveyor for powder supply
  • a change between the two powders can be carried out without any problems, advantageously cleaning or a change of a feed hose or the like. is not required.
  • the method according to the invention is used with particular advantage in workpieces which have a light metal surface, namely an aluminum-containing alloy such as AlSi 17 , AlSi 9 , and others, or a gray cast iron surface, a gray cast iron surface being particularly preferred because corresponding cylinder liners have proven to be particularly durable.
  • the aluminum-containing alloy of the adhesion promoter is a nickel-aluminum alloy (nickel-based alloys), a copper-aluminum alloy - not according to the invention with iron, a cobalt-aluminum alloy, a silicon-aluminum alloy, a magnesium-cobalt-aluminum alloy, a silver Aluminum alloy, or an aluminum bronze.
  • the adhesion promoter preferably has no further components, so that the percentages of molybdenum and the aluminum-containing alloy preferably add up to 100%. It is further preferred that 0.2-5% boron is added to the adhesion promoter to support the adhesive effect. According to the invention, the molybdenum, the aluminum-containing alloy and boron add up to 100% by weight.
  • the silicon content is preferably 8 to 25% by weight, based on the adhesion promoter.
  • the base material comprises iron or an iron alloy, e.g. Steel, preferably a low-alloy steel or an iron-based steel, in particular 100Cr6, with 0.05 to 1.5% by weight carbon; 0.05 to 3.5 wt% manganese; 0.05 to 3.0 wt% chromium; 0.01 to 1% by weight silicon and / or 0.001 to 0.4% by weight sulfur and / or a chromium steel with an iron base and 0.05 to 0.8% by weight carbon; 0-3% by weight molybdenum; 0.05 to 1.8 wt% manganese; 11.5 to 18 wt% chromium; 0.01 to 1 wt .-% silicon and / or 0.002 to 0.2 wt .-% sulfur.
  • These are particularly suitable as a protective layer, in particular for cylinder components, and interact with the adhesion promoter
  • adhesion promoter and the base material based on the weight, in a ratio of approximately 10:90, 20:80, 30:70, 40:60 or 50:50 in the powder mixture of adhesion promoter and base material available.
  • the method comprises a further step (c) in which a layer of the base material is applied to the surface of the substrate by means of the thermal coating method Step (b) generated coating is applied.
  • Step (b) generated coating is applied.
  • the thermal coating method is plasma spraying.
  • plasma spraying an anode and up to three cathodes are usually separated by a narrow gap in a plasma torch.
  • An arc is generated between the anode and cathode by means of a direct voltage.
  • the gas or gas mixture flowing through the plasma torch is passed through the arc and ionized in the process.
  • the dissociation, or subsequent ionization generates a highly heated (up to 30,000 K), electrically conductive gas from positive ions and electrons.
  • Powder (usual particle size distribution: 5-200 ⁇ m, grain size down to 100 nm is possible) is injected into this plasma jet, which is melted by the high plasma temperature.
  • the plasma stream entrains the powder particles and hurls them onto the workpiece to be coated.
  • the gas molecules return to a stable state after a very short time and the plasma temperature drops again after a short distance.
  • the plasma spray coating is carried out in a normal atmosphere, an inert atmosphere (under protective gas such as argon), in a vacuum or under water, the coating under a normal (compressed air) atmosphere being preferred, since this reduces the process costs compared to the other variants.
  • the speed, temperature and the composition of the plasma gas are important for the layer quality.
  • Gases used can be argon, nitrogen, hydrogen or helium.
  • Plasma spraying creates optimally constructed layers for cylinder liners with a non-communicating microporosity, which after the manufacturing process serves as an oil retention volume on the smoothly honed cylinder surface.
  • a conventional honing groove structure as an oil retention volume can be dispensed with. Due to its universal applicability, plasma spraying has a large industrial application and has advantages such as flexible material selection (the process allows a wide range of spraying materials that are easy to produce and mix), high particle impact speeds, good adhesive strength of the applied layers and, due to the compact size Burner design, the possibility of carrying out an inner coating even with small diameters, has become the most important of all thermal spray processes.
  • Wire spraying processes are an alternative for cylinder raceway coatings, however layers are produced here that have a significantly lower porosity compared to plasma spraying layers and thus have only a few large pores on the raceway surface after honing, which in most cases are insufficient as oil retention volumes.
  • Another disadvantage is the strong oxide formation, particularly in the single-wire process (PTWA or RSW), if the layers are sprayed without protective gas and can thus lead to increased susceptibility to corrosion. This oxide formation does not lead to a continuous oxide layer.
  • the method particularly advantageously does not include any pretreatment of the surface of the workpiece, in particular no roughening of the surface of the workpiece.
  • the method according to the invention does not exclude the possibility of pretreatment, but the method according to the invention enables the pretreatment of the workpiece surface, in particular by roughening the workpiece surface, to be omitted. Failure to pretreat the surface of the workpiece, in particular refraining from roughening the surface, leads not only to high process cost savings, but also to an improvement in the quality of the coated surface.
  • finely spindleed surfaces can also be coated with the method according to the invention if a pretreatment, in particular roughening, by which the finely spindle surface would be changed, in particular destroyed, is omitted.
  • the thermal coating process is preferably carried out without active air conditioning.
  • the cylinder crankcase heats up in the process, i.e. during the coating process, for example through molten plasma powder and cools down automatically. After coating, the cylinder crankcase is approx. 100 ° C to a maximum of 140 ° C warm.
  • the cylinder crankcase is preferably upright for coating and is received on the oil pan side.
  • the cylinder crankcase is preferably accommodated on the top deck.
  • the cylinder crankcase can preferably also be accommodated on the transmission side.
  • Another aspect of the invention relates to a cylinder crankcase with a cylinder raceway which has a coating produced according to the method of the invention.
  • the coating of the component according to the invention either has a mixed layer arranged on a surface of the cylinder raceway, which comprises the base material and the adhesion promoter made of molybdenum and aluminum-containing alloy.
  • the Coating a first layer of the adhesion promoter and a second layer, which comprises the base material but not the adhesion promoter.
  • the coating greatly improves the frictional resistance of the coated surface and at the same time has a high level of resistance, since the coating shows very good adhesion to the workpiece surface.
  • Adhesive tensile values of 50 to> 70 MPa are achieved with the method according to the invention. In this way, the adhesive tensile values of a conventional process, in which the adhesion of the coating is achieved by roughening the surface beforehand and without an adhesion promoter, are achieved from 20 to> 70 MPa and even exceeded in the lower range.
  • the first and the second layer are applied to the workpiece surface using a thermal coating method.
  • Another aspect of the invention relates to an engine which has a cylinder crankcase according to the invention.
  • FIGS. 1 to 6 show light microscope images of cross sections (longitudinal sections) of a coated workpiece 1 (cylinder raceway) of a component 10 (cylinder crankcase) in different embodiments.
  • a part of the workpiece 1 is shown, on the metallic surface of which a coating 2 is arranged.
  • the coating 2 can be applied, for example, using the method according to the invention.
  • the workpiece 1 shown comprises a metallic surface made of a light metal alloy, more precisely an aluminum-containing alloy, namely AlSi 17 .
  • Coating 2 was applied to this surface in one process step.
  • Coating 2 shown comprises a low-alloy steel as the base material and an adhesion promoter which is integrated in the layer.
  • Coating 2 shown was produced with the method according to the invention in that a powder mixture of base material and adhesion promoter was applied to the metallic surface by means of plasma spraying. The particles of the powder mixture melted and bonded on the surface to form a uniform mixed layer 3.
  • FIG. 2 A workpiece 1 is shown which has the same coating 2 as that in FIG Figure 1 workpiece 1 shown. However, the surface of the workpiece 1 is made of gray cast iron.
  • the Figures 3 and 4 each show a light microscope image of a cross section (longitudinal section) of a coated workpiece 1 according to a further embodiment of the invention.
  • the Figures 3 and 4 each show a workpiece 1 with a two-layer coating 2.
  • the coating 2 here comprises a mixed layer 3, which comprises a mixture of the base material and the adhesion promoter.
  • the mixed layer 3 essentially corresponds to the mixed layer 3 the one in the Figures 1 and 2 shown execution, but is in contrast to this layer thickness between 20 and 55 microns much thinner.
  • a base material layer 4, which essentially consists of the base material, is arranged on the mixed layer 3 composed of base material and adhesion promoter. This is many times thicker than the mixed layer 3.
  • Preferred layer thicknesses for powder plasma spray layers are in the range from 120 to 180 ⁇ m, in particular in the range from 140 to 160 ⁇ m and at most 300 ⁇ m, and in the case of wire spray layers preferably in the range from 150 to 300 ⁇ m, especially in the range from 170 to 250 ⁇ m, up to a maximum of 500 ⁇ m.
  • the mixed layer 3 has the function of increasing the adhesion of the coating 2, while the base material layer 4 determines the properties of the workpiece to the outside, such as the frictional resistance.
  • the Figures 3 and 4 differ in the material of the coated workpiece. While the coating is 2 in Figure 3 is arranged on a light metal alloy, for example an aluminum-containing alloy such as AlSi 17 , the material of the workpiece 1 in FIG Figure 4 shown execution around a gray cast iron.
  • the coatings 2 shown can be applied using the method according to the invention.
  • a powder mixture of adhesion promoter and base material is first provided and arranged on the surface of the workpiece 1 by means of a thermal coating process, such as plasma spraying, so that a homogeneous mixing layer 3 is formed.
  • a powder which contains the base material but not the adhesion promoter is then provided and is likewise applied to the mixing layer 3 using a, preferably the same, thermal method.
  • the device that carries out the thermal coating process can be equipped with a double powder conveyor, so that the same device can be used for both coating steps.
  • the Figures 5 and 6 each show a light microscope image of a cross section (longitudinal section) of a coated workpiece 1 according to further embodiments of the invention.
  • the Figures 5 and 6 show the same coating 2, but differ in the material of the workpiece 1, which in Figure 5 a light metal alloy (in particular AlSi 17 ) and in the workpiece 1 Figure 6 includes a gray cast iron.
  • the coating 2 in the Figures 5 and 6 is also designed as a two-layer system, the first layer arranged on the workpiece surface being an adhesive base 5 on which a base material layer 6 is deposited, which contains the base material.
  • the primer 5 has the adhesion promoter and contains no base material.
  • the base material of the embodiments shown is a low-alloy steel, such as (preferably iron-based steel with 0.05 to 1.5% by weight of carbon; 0.05 to 3.5% by weight of manganese; 0.05 to 3.0% by weight of chromium; 0.01 to 1% by weight silicon and / or 0.001 to 0.4% by weight sulfur and / or a chrome steel with an iron base and 0.05 to 0.8% by weight carbon; 0 - 3% by weight Molybdenum; 0.05 to 1.8% by weight manganese; 11.5 to 18% by weight chromium; 0.01 to 1% by weight silicon and / or 0.002 to 0.2% by weight sulfur.
  • a low-alloy steel such as (preferably iron-based steel with 0.05 to 1.5% by weight of carbon; 0.05 to 3.5% by weight of manganese; 0.05 to 3.0% by weight of chromium; 0.01 to 1% by weight silicon and / or 0.001 to 0.4% by weight sulfur and / or a chrome steel with an iron base and 0.05
  • the ratio of adhesion promoter and Base material has in the mixed layers 3 of the Figures 1 to 4 preferably a ratio of 20% by weight of adhesion promoter to 80% by weight of base material.
  • the adhesion promoter is contained in the mixed layer 3 in a range from 10 to 80% by weight and the base material accordingly in the range from 20 to 90% by weight.
  • the adhesion promoter is a mixture of molybdenum and a Ni5Al alloy (95% nickel% and 5% aluminum) or a mixture of molybdenum NiAI alloy and the base material as described above.
  • nickel in the aluminum-containing alloy can be replaced by cobalt, copper or silver.
  • Molybdenum is 20 to 80 wt .-% and the aluminum-containing alloy in a range of 20 to 80 wt .-% in the coupling agent.
  • layers of this type can also be produced by means of wire spray processes such as LDS, PTWA and RSW, in that the adhesion promoter is positioned in a cored wire or in that wire spray layers can be sprayed onto an adhesive base applied by a plasma spray process.
  • wire spray processes such as LDS, PTWA and RSW, in that the adhesion promoter is positioned in a cored wire or in that wire spray layers can be sprayed onto an adhesive base applied by a plasma spray process.

Description

Die Erfindung betrifft ein Verfahren zur Beschichtung einer Zylinderlaufbahn eines Zylinderkurbelgehäuses, ein Zylinderkurbelgehäuse sowie einen Motor.The invention relates to a method for coating a cylinder liner of a cylinder crankcase, a cylinder crankcase and an engine.

Zum Beschichten von Werkstücken werden heutzutage häufig thermische Spritzverfahren eingesetzt wie beispielsweise Plasmaspritzen; Hochgeschwindigkeitsflammspritzen (HVOF), Lichtbogenspritzen und Lichtbogendrahtspritzen. Mit diesen Verfahren werden Schichten auf einem Werkstück erzeugt, wobei das Werkstück beispielsweise metallisch ist und die Beschichtung metallisch, keramisch oder auch eine Mischung aus beiden sein kann. Oft umfasst die Beschichtung mehrere einzelne Schichten, die übereinander angeordnet sind und in der Regel unterschiedliche Funktionalitäten haben. So sind z.B. thermische Schutzschichten (TBC) bekannt, Korrosionsschutzschichten, Erosionsschutzschichten oder auch Gleitschichten, welche das Aneinandergleiten von Gegenlaufkörpern vereinfachen. Ein Anwendungsbeispiel ist hier das Beschichten von Zylinderlaufflächen in Verbrennungsmotoren mit Schichten die gute Schmier- und Reibeigenschaften haben, wodurch die Laufeigenschaften des Kolbens im Zylinder verbessert werden.Nowadays, thermal spraying processes are often used to coat workpieces, such as plasma spraying; High speed flame spraying (HVOF), arc spraying and arc wire spraying. With these methods, layers are produced on a workpiece, the workpiece being, for example, metallic and the coating being metallic, ceramic or a mixture of the two. The coating often comprises several individual layers, which are arranged one above the other and generally have different functionalities. For example, Thermal protective layers (TBC) known, corrosion protection layers, erosion protection layers or sliding layers, which simplify the sliding together of counter-rotating bodies. An application example is the coating of cylinder running surfaces in internal combustion engines with layers that have good lubricating and friction properties, which improves the running properties of the piston in the cylinder.

Im Fahrzeugbau und insbesondere bei der Fertigung von Zylinderkurbelgehäusen (ZKG) wird mehr und mehr auf Leichtbau gesetzt. Dazu werden Aluminium-Zylinderkurbelgehäuse eingesetzt, die im Bereich der Zylinderlaufbahn eine Beschichtung aufweisen. Der Effekt der Beschichtung ist neben einer Robustheitssteigerung der Laufbahn eine deutlich reduzierte Reibung im Bereich der Kolbengruppe und damit verbunden eine Senkung des CO2-Ausstoßes, sowie positive Effekte gegenüber korrosiven Medien. Gängige thermische Beschichtungsverfahren sind das Pulver-Plasmaspritzen, Drahtspritzverfahren wie Plasma-Transfer-Wire-Arc (PTWA) und Lichtbogen-Draht-Spritzen (LDS) oder Hochgeschwindigkeitsflammspritzen.In vehicle construction and in particular in the production of cylinder crankcases (ZKG), lightweight construction is increasingly used. For this purpose, aluminum cylinder crankcases are used, which have a coating in the area of the cylinder race. The effect of the coating is, in addition to increasing the robustness of the raceway, a significantly reduced friction in the area of the piston group and associated reduction in CO 2 emissions, as well as positive effects against corrosive media. Common thermal coating processes are powder plasma spraying, wire spraying processes such as plasma transfer wire arc (PTWA) and arc wire spraying (LDS) or high-speed flame spraying.

DE 24 32 125 A1 beschreibt einen selbstverschweißenden und selbstverwachsenden Flammspritz-Verbundwerkstoff, der Aluminium und Molybdän und zumindest eines der Metalle Nickel, Kupfer und Eisen sowie als Bindemittel einen Lack enthält. Durch die Eigenschaft der Selbstverschweißung und Selbstverwachsung soll eine Oberflächenvorbereitung außer sorgfältiger Reinigung nicht erforderlich sein. DE 24 32 125 A1 describes a self-welding and self-waxing flame spray composite material which contains aluminum and molybdenum and at least one of the metals nickel, copper and iron as well as a paint as a binder. Due to the property of self-welding and self-waxing, surface preparation other than careful cleaning should not be necessary.

Aus DE 694 23 373 T2 ist ein thermisches Verbundspritzpulver zum thermischen Spritzen von Zylinderinnenwänden bekannt, das Aluminium und ein Metall auf Eisenbasis, nämlich Gusseisen oder eine Eisen-Molybdänlegierung, sowie ein organisches Bindemittel umfasst.Out DE 694 23 373 T2 A thermal composite spray powder for thermal spraying of cylinder inner walls is known, which comprises aluminum and a metal based on iron, namely cast iron or an iron-molybdenum alloy, as well as an organic binder.

US 2, 588,422 A offenbart die Herstellung eines Aluminiumzylinderblocks, wobei die Bohrungen zunächst mit Molybdän mit einem Drahtspritzverfahren beschichtet werden und nachfolgend mit einem Hartmetall, wie etwa Stahl. US 2, 588,422 A discloses the manufacture of an aluminum cylinder block, the holes first being coated with molybdenum using a wire spray process and subsequently with a hard metal, such as steel.

Vor einer thermischen Beschichtung von Zylinderbohrungen in Kurbelgehäusen aus Aluminium und auch aus Grauguss, wie beispielsweise aus DE 103 08 563 B3 , DE 28 41 552 A1 und DE 196 37 737 A1 bekannt, wird ein Aufrauprozess zur Verklammerung der Beschichtung in der Oberfläche benötigt. Der Aufrauprozess wird durch strahlende Prozesse mittels Korund oder Wasser (Mitteldruck-/Hochdruck-Wasserstrahlen), Laserstrahlaufrauen oder Aufrauen mit einer geometrisch definierten Schneide durchgeführt. Die beschriebenen Verfahren haben jedoch den Nachteil, dass das Strahlmedium aufwändig aufbereitet werden muss, und ferner die Prozesse durch zusätzliche und umfangreiche Analyseverfahren überwacht und große Mengen an Stäuben, Spänen und Schlämmen entfernt und entsorgt werden müssen. Weiterhin müssen hohe Investitionen zur Installation dieser Aufrauprozesse getätigt werden.Before thermal coating of cylinder bores in crankcases made of aluminum and also of gray cast iron, such as from DE 103 08 563 B3 , DE 28 41 552 A1 and DE 196 37 737 A1 known, a roughening process is required to clamp the coating in the surface. The roughening process is carried out by blasting processes using corundum or water (medium-pressure / high-pressure water jets), laser beam roughening or roughening with a geometrically defined cutting edge. However, the methods described have the disadvantage that the blasting medium has to be prepared in a complex manner, and furthermore the processes have to be monitored by additional and extensive analysis methods and large amounts of dusts, chips and sludges have to be removed and disposed of. Furthermore, large investments have to be made to install these roughening processes.

Weiterhin nachteilig ist die beim mechanischen Aufrauen eingesetzte Emulsionsspülung der Schneiden häufig nicht effektiv genug, so dass immer wieder Späne im Aufrauprofil verbleiben und im Beschichtungsprozess den Schichtaufbau und die Schichtqualität negativ beeinflussen. Gleiches gilt für im Wasser- beziehungsweise Laserstrahlaufrauverfahren hergestellte Oberflächen die starke Vertiefungen und wulst-/spritzerartige Überhöhungen zeigen. Zudem müssen hohe Investitionen zur Installation dieser Aufrauprozesse getätigt werden.Another disadvantage is that the emulsion rinsing of the cutting edges used in mechanical roughening is often not effective enough, so that chips remain in the roughening profile again and again and negatively influence the layer structure and the layer quality in the coating process. The same applies to surfaces manufactured in the water or laser beam roughening process which show strong depressions and bead-like / spatter-like elevations. In addition, large investments have to be made to install these roughening processes.

Der Erfindung liegt nun die Aufgabe zugrunde, ein Verfahren zur Beschichtung eines metallischen Werkstücks, nämlich einer Zylinderlaufbahn eines Zylinderkurbelgehäuses bereitzustellen, bei dem eine Vorbehandlung und insbesondere eine Aufrauung der Oberfläche entbehrlich sind.The invention is based on the object of providing a method for coating a metallic workpiece, namely a cylinder track of a cylinder crankcase, in which a pretreatment and in particular roughening of the surface are unnecessary.

Diese Aufgabe wird mit einem Verfahren mit den Merkmalen des ersten unabhängigen Anspruchs gelöst.This object is achieved with a method having the features of the first independent claim.

Somit betrifft ein erster Aspekt der Erfindung ein Verfahren zur Beschichtung einer aus Grauguss oder einer Aluminium-haltigen Leichtmetalllegierung bestehenden Zylinderlaufbahn eines Zylinderkurbelgehäuses umfassend in einem Schritt (a) das Bereitstellen eines pulverförmigen Basismaterials, wobei das Basismaterial Eisen oder eine Eisenlegierung ist, und eines pulverförmigen Haftvermittlers. Der Haftvermittler umfasst eine Mischung aus 20 bis 80 Gew.-% Molybdän; 20 bis 80 Gew.-% einer Aluminium-haltigen Legierung, die ausgewählt ist aus einer Nickel-Aluminiumlegierung NiAl, insbesondere Ni(95%)AI(5%), einer Kupfer-Aluminiumlegierung CuAl, insbesondere Cu(90%)AI(10%), einer Kobalt-Aluminiumlegierung, einer Magnesium-Kobalt-Aluminiumlegierung einer Silizium-Aluminiumlegierung, einer Silber-Aluminiumlegierung und einer Aluminium-Bronze; und optional 0,2 bis 5 Gew.-% Bor, wobei sich das Molybdän, die Aluminium-haltige Legierung und Bor zu 100 Gew.-% addieren. Besonders bevorzugt wird dabei der Einsatz von Ni(95%)AI(5%) als Aluminium-haltige Legierung für den Haftvermittler. Ferner umfasst das erfindungsgemäße Verfahren das Aufbringen des Basismaterials und des Haftvermittlers auf die Zylinderlaufbahn des Zylinderkurbelgehäuses mittels eines thermischen Beschichtungsverfahrens in einem Schritt (b), wobei entweder eine Schicht aus einer Pulvermischung aus dem Haftvermittler und dem Basismaterial auf der der Zylinderlaufbahn angeordnet wird oder eine erste Schicht umfassend den Haftvermittler auf der Zylinderlaufbahn angeordnet und anschließend eine zweite Schicht umfassend das Basismaterial auf der ersten Schicht angeordnet wird.Thus, a first aspect of the invention relates to a method for coating a cylinder liner of a cylinder crankcase consisting of gray cast iron or an aluminum-containing light metal alloy, comprising in a step (a) the provision of a powdery base material, the base material being iron or an iron alloy, and a powdery adhesion promoter . The coupling agent comprises a mixture of 20 to 80% by weight of molybdenum; 20 to 80% by weight of an aluminum-containing alloy which is selected from a nickel-aluminum alloy NiAl, in particular Ni (95%) Al (5%), a copper-aluminum alloy CuAl, in particular Cu (90%) Al (10 %), a cobalt-aluminum alloy, a magnesium-cobalt-aluminum alloy, a silicon-aluminum alloy, a silver-aluminum alloy and an aluminum-bronze; and optionally 0.2 to 5% by weight of boron, the molybdenum, the aluminum-containing alloy and boron adding up to 100% by weight. The use of Ni (95%) Al (5%) as an aluminum-containing alloy for the adhesion promoter is particularly preferred. Furthermore, the method according to the invention comprises applying the base material and the adhesion promoter to the cylinder race of the cylinder crankcase by means of a thermal coating method in step (b), wherein either a layer of a powder mixture of the adhesion promoter and the base material on which the cylinder race is arranged or a first one Layer comprising the adhesion promoter arranged on the cylinder track and then a second layer comprising the base material is arranged on the first layer.

Thermische Beschichtungsverfahren sind das Pulver-Plasmaspritzen, Drahtspritzverfahren wie Plasma-Transfer-Wire-Arc (PTWA) und Lichtbogen-Draht-Spritzen (LDS) oder Hochgeschwindigkeitsflammspritzen.Thermal coating processes are powder plasma spraying, wire spraying processes such as plasma transfer wire arc (PTWA) and arc wire spraying (LDS) or high-speed flame spraying.

Überraschend wurde festgestellt, dass eine Mischung aus Molybdän und einer Aluminium-haltigen Legierung für Beschichtungen zur Verschleißreduzierung derart als Haftvermittler wirkt, dass keine Vorbehandlung der Zylinderlaufbahn nötig ist. Auch ist die Oberflächengüte für das erfindungsgemäße Beschichten irrelevant und somit ist keine Mindestoberflächenrauigkeit erforderlich. Daher kann durch das erfindungsgemäße Verfahren die Prozessierung von beschichteten Zylinderkurbelgehäusen stark vereinfacht werden.It was surprisingly found that a mixture of molybdenum and an aluminum-containing alloy for coatings to reduce wear acts as an adhesion promoter in such a way that no pretreatment of the cylinder race is necessary. The surface quality is also irrelevant for the coating according to the invention and therefore no minimum surface roughness is required. Therefore, the processing of coated cylinder crankcases can be greatly simplified by the inventive method.

Die genannten Haftvermittler sorgen teilweise, wie im Fall von NiAl, durch exotherme Reaktion der Komponenten untereinander, insbesondere in Verbindung mit Molybdän zu einer sehr guten Haftung, wobei sich insbesondere Ni(95%)AI(5%) als geeignet erwiesen hat.Some of the adhesion promoters mentioned, as in the case of NiAl, ensure very good adhesion by exothermic reaction of the components with one another, in particular in connection with molybdenum, Ni (95%) Al (5%) in particular having proven suitable.

Während des Beschichtens erfolgt jedoch nach keiner Ausführungsform der Erfindung eine Selbstverwachsung oder Selbstverschweißung der Schicht mit dem Zylinderkurbelgehäuse, es werden daher keine intermetallischen Bindungen erzeugt.According to no embodiment of the invention, however, the layer does not self-grow or self-weld during the coating, and therefore no intermetallic bonds are produced.

Insbesondere ist ein Prozessschritt zur Vorbehandlung, der einer Beschichtung des Werkstücks vorgeschaltet ist, nicht notwendig und kann eingespart werden. Diese Einsparung führt zu wirtschaftlichen, insbesondere finanziellen Vorteilen, da die Prozesszeit insgesamt reduziert wird. Handelt es sich bei der Vorbehandlung um eine Aufrauung des Materials, so entfällt zudem eine aufwendige Entsorgung der beim Aufrauprozess verwendeten Materialien. Bei Verwendung des erfindungsgemäßen Verfahrens wird zusätzlich eine Qualitätssteigerung des Werkstücks erzielt, da Fehler auf der Werkstückoberfläche, die durch die Vorbehandlung, insbesondere das Aufrauen der Oberfläche, entstehen können, gänzlich vermieden werden. Somit können mit dem erfindungsgemäßen Verfahren auch feingespindelte Oberflächen ohne Qualitätseinbußen beschichtet werden.In particular, a process step for pretreatment, which precedes a coating of the workpiece, is not necessary and can be saved. This saving leads to economic, in particular financial advantages, since the process time is reduced overall. If the pretreatment involves roughening the material, there is also no need to dispose of the materials used in the roughening process. When using the method according to the invention, an increase in the quality of the workpiece is additionally achieved, since errors on the workpiece surface, which can occur as a result of the pretreatment, in particular the roughening of the surface, are completely avoided. Thus, with the method according to the invention, finely spindleed surfaces can also be coated without loss of quality.

Die mit dem erfindungsgemäßen Verfahren erzeugte Beschichtung dient als Schutzschicht für eine Zylinderlaufbahn eines Zylinderkurbelgehäuses. Vorzugsweise wird durch die Schutzschicht die Reibfestigkeit erhöht. Die Eigenschaften der Schutzschicht werden dabei maßgeblich durch das Basismaterial bestimmt.The coating produced with the method according to the invention serves as a protective layer for a cylinder track of a cylinder crankcase. The protective layer preferably increases the friction resistance. The properties of the protective layer are largely determined by the base material.

Erfindungsgemäß wird der Haftvermittler entweder gemeinsam mit dem Basismaterial auf der metallischen Werkstückoberfläche (Zylinderlaufbahn) angeordnet und liegt dann gemeinsam mit dem Basismaterial in einer Mischschicht auf der Werkstückoberfläche vor, so dass sich ein in die Schutzschicht integrierter Haftgrund bildet. Alternativ oder zusätzlich sieht das erfindungsgemäße Verfahren vor, den Haftvermittler in einer gesonderten Schicht ohne Basismaterial, als Haftgrund auf der Werkstückoberfläche anzuordnen und anschließend auf den Haftgrund eine Schutzschicht anzuordnen, welche vorzugsweise nur das Basismaterial, aber zumindest nicht den Haftvermittler, aufweist.According to the invention, the adhesion promoter is either arranged together with the base material on the metallic workpiece surface (cylinder raceway) and is then present together with the base material in a mixed layer on the workpiece surface, so that an adhesive base integrated in the protective layer is formed. As an alternative or in addition, the method according to the invention provides for the adhesion promoter to be arranged in a separate layer without base material as a primer on the workpiece surface and then for a protective layer to be arranged on the primer, which preferably has only the base material, but at least not the adhesion promoter.

Der Haftvermittler und das Basispulver liegen als physikalisches Gemisch vor, bilden also keine chemischen Verbindungen bzw. Legierungen aus.The adhesion promoter and the base powder are present as a physical mixture, i.e. they do not form any chemical compounds or alloys.

Die Trennung von Haftvermittler und Basismaterial in zwei Schichten bietet mehrere Vorteile. Zum einen kann die Wirkung des Haftvermittlers erhöht werden und somit die Haftzugwerte der Beschichtung auf der Werkstückoberfläche verbessert werden, zum anderen kommt der Haftvermittler bei einem getrennten Aufbringen der einzelnen Schichten nicht mit der Umgebung des Werkstücks in Kontakt. Eine Wechselwirkung des Haftvermittlers mit der Umgebung des Werkstücks kann somit vermieden werden.The separation of adhesion promoter and base material in two layers offers several advantages. On the one hand, the effect of the adhesion promoter can be increased and thus the adhesive tensile values of the coating on the workpiece surface can be improved, on the other hand the adhesion promoter does not come with the separate application of the individual layers Surrounding the workpiece. Interaction of the adhesion promoter with the surroundings of the workpiece can thus be avoided.

Vorzugsweise findet die Beschichtung aller genannten Schichten mit demselben thermischen Beschichtungsverfahren statt. Somit sind die Nachteile eines zusätzlichen Beschichtungsschritts vernachlässigbar, insbesondere dann, wenn besondere Vorkehrungen getroffen werden, wie beispielsweise die Verwendung eines Plasmabrenners mit Doppelpulverförderer zur Pulverbereitstellung, um den Mehraufwand eines zusätzlichen Beschichtungsschritts möglichst gering zu halten. So kann bei der Bereitstellung von beispielsweise einem Fass Haftvermittler und einem Fass Basismaterial ein Wechsel zwischen beiden Pulvern problemlos erfolgen, wobei vorteilhafterweise eine Reinigung oder ein Wechsel eines Zuführschlauches o.ä. nicht erforderlich ist.All of the layers mentioned are preferably coated using the same thermal coating method. The disadvantages of an additional coating step are thus negligible, especially when special precautions are taken, such as the use of a plasma torch with a double powder conveyor for powder supply, in order to keep the additional expenditure of an additional coating step as low as possible. For example, when a barrel of adhesion promoter and a barrel of base material are provided, a change between the two powders can be carried out without any problems, advantageously cleaning or a change of a feed hose or the like. is not required.

Es zeigte sich, dass das erfindungsgemäße Verfahren mit besonderem Vorteil bei Werkstücken verwendet wird, die eine Leichtmetalloberfläche, nämlich eine Aluminium-haltige Legierung wie beispielsweise AlSi17, AlSi9, und weitere, oder eine Graugussoberfläche aufweisen, wobei eine Graugussoberfläche besonders bevorzugt ist, da entsprechende Zylinderlaufbahnen sich als besonders haltbar erweisen.It was found that the method according to the invention is used with particular advantage in workpieces which have a light metal surface, namely an aluminum-containing alloy such as AlSi 17 , AlSi 9 , and others, or a gray cast iron surface, a gray cast iron surface being particularly preferred because corresponding cylinder liners have proven to be particularly durable.

Bei der Aluminium-haltigen Legierung des Haftvermittlers handelt es sich um eine Nickel-Aluminiumlegierung (Nickelbasislegierungen), eine Kupfer-Aluminiumlegierung -nicht erfindungsgemäß mit Eisen, eine Kobalt-Aluminiumlegierung, eine Silizium-Aluminiumlegierung, eine Magnesium-Kobalt-Aluminiumlegierung, eine Silber-Aluminiumlegierung, oder eine Aluminium-Bronze.The aluminum-containing alloy of the adhesion promoter is a nickel-aluminum alloy (nickel-based alloys), a copper-aluminum alloy - not according to the invention with iron, a cobalt-aluminum alloy, a silicon-aluminum alloy, a magnesium-cobalt-aluminum alloy, a silver Aluminum alloy, or an aluminum bronze.

Besonders gute Ergebnisse, insbesondere gute Haftzugwerte der Beschichtung des Basismaterials, werden erfindungsgemäß erzielt, indem Molybdän im Bereich von 20 bis 80 Gew.-% und die Aluminium-haltige Legierung im Bereich von 20 bis 80 Gew.-% bezogen auf den Haftvermittler vorliegt. Diese Angaben beziehen sich bevorzugt auf das bereitgestellte pulverförmige Material. Vorzugsweise weist der Haftvermittler neben Molybdän und Aluminium der Aluminium-haltigen Legierung keine weiteren Komponenten auf, sodass sich die prozentualen Anteile von Molybdän und der Aluminium-haltigen Legierung vorzugsweise zu 100 % addieren. Ferner ist bevorzugt, dass 0,2-5 % Bor dem Haftvermittlers zur Unterstützung der Haftwirkung zugesetzt werden. Erfindungsgemäß addieren sich das Molybdän, die Aluminium-haltige Legierung und Bor zu 100 Gew.-%.Particularly good results, in particular good tensile adhesion values of the coating of the base material, are achieved according to the invention by using molybdenum in the range from 20 to 80% by weight and the aluminum-containing alloy in the range from 20 to 80% by weight, based on the adhesion promoter. This information relates preferably to the powdery material provided. In addition to molybdenum and aluminum of the aluminum-containing alloy, the adhesion promoter preferably has no further components, so that the percentages of molybdenum and the aluminum-containing alloy preferably add up to 100%. It is further preferred that 0.2-5% boron is added to the adhesion promoter to support the adhesive effect. According to the invention, the molybdenum, the aluminum-containing alloy and boron add up to 100% by weight.

Ebenfalls gute Ergebnisse werden mit einer Silizium-Aluminiumlegierung erzielt, vorzugsweise liegt dabei der Silizium-Anteil bei 8 bis 25 Gew.-% bezogen auf den Haftvermittler.Good results are also achieved with a silicon-aluminum alloy; the silicon content is preferably 8 to 25% by weight, based on the adhesion promoter.

Das Verfahren ist mit allen bekannten Beschichtungen durchführbar, die geeignet sind, einen Verschleiß der Werkstückoberfläche durch Temperatur und/oder Reibungsbeanspruchung zu reduzieren. Erfindungsgemäß umfasst das Basismaterial Eisen oder eine Eisenlegierung, z.B. Stahl, vorzugsweise ein niedrig legierter Stahl bzw. ein eisenbasierter Stahl, insbesondere 100Cr6, mit 0,05 bis 1.5 Gew.-% Kohlenstoff; 0,05 bis 3.5 Gew.-% Mangan; 0.05 bis 3,0 Gew.-% Chrom; 0,01 bis 1 Gew.-% Silizium und/oder 0,001 bis 0,4 Gew.-% Schwefel und/oder einen Chromstahl mit einer Eisenbasis und 0,05 bis 0.8 Gew.-% Kohlenstoff; 0 - 3 Gew.-% Molybdän; 0,05 bis 1.8 Gew.-% Mangan; 11.5 bis 18 Gew-% Chrom ; 0,01 bis 1 Gew.-% Silizium und/oder 0,002 bis 0,2 Gew.-% Schwefel. Diese sind als Schutzschicht insbesondere für Zylinderbauteile besonders gut geeignet und wechselwirken mit den genannten Haftvermittlern derart, dass eine Haftung insbesondere auf Grauguss aber auch auf Leichtmetalloberflächen deutlich verbessert wird.The method can be carried out with all known coatings which are suitable for reducing wear on the workpiece surface due to temperature and / or frictional stress. According to the invention the base material comprises iron or an iron alloy, e.g. Steel, preferably a low-alloy steel or an iron-based steel, in particular 100Cr6, with 0.05 to 1.5% by weight carbon; 0.05 to 3.5 wt% manganese; 0.05 to 3.0 wt% chromium; 0.01 to 1% by weight silicon and / or 0.001 to 0.4% by weight sulfur and / or a chromium steel with an iron base and 0.05 to 0.8% by weight carbon; 0-3% by weight molybdenum; 0.05 to 1.8 wt% manganese; 11.5 to 18 wt% chromium; 0.01 to 1 wt .-% silicon and / or 0.002 to 0.2 wt .-% sulfur. These are particularly suitable as a protective layer, in particular for cylinder components, and interact with the adhesion promoters mentioned in such a way that adhesion, in particular on gray cast iron but also on light metal surfaces, is significantly improved.

In einer bevorzugten Ausgestaltung der Erfindung ist vorgesehen, dass der Haftvermittler und das Basismaterial bezogen auf das Gewicht in einem Verhältnis von ungefähr 10 : 90, 20 : 80, 30 : 70, 40 : 60 oder 50 : 50 in der Pulvermischung aus Haftvermittler und Basismaterial vorliegen.In a preferred embodiment of the invention it is provided that the adhesion promoter and the base material, based on the weight, in a ratio of approximately 10:90, 20:80, 30:70, 40:60 or 50:50 in the powder mixture of adhesion promoter and base material available.

Damit ist sichergestellt, dass die wünschenswerten Eigenschaften des Basismaterials, insbesondere die Verbesserung der Verschleißeigenschaften der Werkstückoberfläche durch die Anwesenheit des Haftvermittlers nicht beeinträchtigt werden. Besonders gute Eigenschaften einer Schutzschicht, in der das Basismaterial und der Haftvermittler gemischt vorliegen, werden erzielt, wenn der Haftvermittler zu 20(±5) % und das Basismaterial zu 80(±5) % in der Pulvermischung vorliegen. Eine mit dem erfindungsgemäßen Verfahren in dieser Ausgestaltung aufgetragene Beschichtung zeigt ein optimales Verhältnis aus Reibfestigkeit und Haftung.This ensures that the desirable properties of the base material, in particular the improvement in the wear properties of the workpiece surface, are not impaired by the presence of the adhesion promoter. Particularly good properties of a protective layer in which the base material and the adhesion promoter are mixed are achieved if the adhesion promoter is 20 (± 5)% and the base material is 80 (± 5)% in the powder mixture. A coating applied with the method according to the invention in this configuration shows an optimal ratio of friction resistance and adhesion.

In einer weiter bevorzugten Ausgestaltung des Verfahrens umfasst das Verfahren, wenn in Schritt (b) eine Pulvermischung aus Basismaterial und Haftvermittler auf die Werkstückoberfläche aufgebracht wird, einen weiteren Schritt (c), in welchem eine Schicht aus dem Basismaterial mittels des thermischen Beschichtungsverfahrens auf die in Schritt (b) erzeugte Beschichtung aufgebracht wird. In dieser bevorzugten Ausgestaltung ist sichergestellt, dass die beschichtete Werkstückoberfläche mit einer Schicht, die das Basismaterial aber nicht den Haftvermittler umfasst, gegen die Umgebung abschließt. Somit können Wechselwirkungen zwischen den Materialien des Haftvermittlers und der Umgebung, wie beispielsweise einem Laufmittel, ausgeschlossen werden. Ferner werden die Eigenschaften des Basismaterials an der Oberfläche des Werkstücks uneingeschränkt genutzt.In a further preferred embodiment of the method, if a powder mixture of base material and adhesion promoter is applied to the workpiece surface in step (b), the method comprises a further step (c) in which a layer of the base material is applied to the surface of the substrate by means of the thermal coating method Step (b) generated coating is applied. In this preferred embodiment, it is ensured that the coated workpiece surface is sealed off from the surroundings by a layer that includes the base material but not the adhesion promoter. Thus, interactions between the materials of the adhesion promoter and the environment, such as one Eluent to be excluded. Furthermore, the properties of the base material on the surface of the workpiece are used without restriction.

In einer besonders bevorzugten Ausgestaltung des Verfahrens ist vorgesehen, dass das thermische Beschichtungsverfahren Plasmaspritzen ist. Beim Plasmaspritzen sind üblicherweise in einem Plasmabrenner eine Anode und bis zu drei Kathoden durch einen schmalen Spalt getrennt. Durch eine Gleichspannung wird ein Lichtbogen zwischen Anode und Kathode erzeugt. Das durch den Plasmabrenner strömende Gas oder Gasgemisch wird durch den Lichtbogen geleitet und hierbei ionisiert. Die Dissoziation, beziehungsweise anschließende Ionisation, erzeugt ein hochaufgeheiztes (bis 30000 K), elektrisch leitendes Gas aus positiven Ionen und Elektronen. In diesem erzeugten Plasmajet wird Pulver (übliche Kornverteilung: 5-200 µm, bei bestimmten Geräten ist auch eine Körnung von bis hinunter zu 100 nm möglich) eingedüst, das durch die hohe Plasmatemperatur aufgeschmolzen wird. Der Plasmastrom reißt die Pulverteilchen mit und schleudert sie auf das zu beschichtende Werkstück. Die Gasmoleküle kehren bereits nach kürzester Zeit wieder in einen stabilen Zustand zurück und so sinkt die Plasmatemperatur bereits nach kurzer Wegstrecke wieder ab. Die Plasmaspritzbeschichtung erfolgt in normaler Atmosphäre, inerter Atmosphäre (unter Schutzgas wie Argon), in Vakuum oder auch unter Wasser, wobei die Beschichtung unter normaler (Druckluft) Atmosphäre bevorzugt ist, da hierdurch die Verfahrenskosten gegenüber den anderen Varianten geringer sind. Für die Schichtqualität sind die Geschwindigkeit, Temperatur als auch die Zusammensetzung des Plasmagases von Bedeutung. Verwendete Gase können Argon, Stickstoff, Wasserstoff oder Helium sein.In a particularly preferred embodiment of the method, it is provided that the thermal coating method is plasma spraying. In plasma spraying, an anode and up to three cathodes are usually separated by a narrow gap in a plasma torch. An arc is generated between the anode and cathode by means of a direct voltage. The gas or gas mixture flowing through the plasma torch is passed through the arc and ionized in the process. The dissociation, or subsequent ionization, generates a highly heated (up to 30,000 K), electrically conductive gas from positive ions and electrons. Powder (usual particle size distribution: 5-200 µm, grain size down to 100 nm is possible) is injected into this plasma jet, which is melted by the high plasma temperature. The plasma stream entrains the powder particles and hurls them onto the workpiece to be coated. The gas molecules return to a stable state after a very short time and the plasma temperature drops again after a short distance. The plasma spray coating is carried out in a normal atmosphere, an inert atmosphere (under protective gas such as argon), in a vacuum or under water, the coating under a normal (compressed air) atmosphere being preferred, since this reduces the process costs compared to the other variants. The speed, temperature and the composition of the plasma gas are important for the layer quality. Gases used can be argon, nitrogen, hydrogen or helium.

Das Plasmaspritzen erzeugt für Zylinderlaufbahnen optimal aufgebaute Schichten mit einer nicht kommunizierenden Mikroporosität, die nach dem Fertigungsprozess als Ölrückhaltevolumen auf der glatt gehonten Zylinderlauffläche dient. Auf eine konventionelle Honriefenstruktur als Ölrückhaltevolumen kann verzichtet werden. Das Plasmaspritzen findet aufgrund seiner universellen Anwendbarkeit ein großes industrielles Einsatzgebiet und hat durch seine Vorteile wie flexible Werkstoffauswahl (Verfahren erlaubt eine breite Palette an Spritzwerkstoffen, die leicht herstellbar und mischbar sind), hohe Partikelaufprallgeschwindigkeiten, gute Haftfestigkeiten der aufgebrachten Schichten sowie, bedingt durch die kompakte Brennerbauweise, der Möglichkeit, eine Innenbeschichtung auch bei kleinen Durchmessern durchzuführen, unter allen thermischen Spritzverfahren die größte Bedeutung erlangt.Plasma spraying creates optimally constructed layers for cylinder liners with a non-communicating microporosity, which after the manufacturing process serves as an oil retention volume on the smoothly honed cylinder surface. A conventional honing groove structure as an oil retention volume can be dispensed with. Due to its universal applicability, plasma spraying has a large industrial application and has advantages such as flexible material selection (the process allows a wide range of spraying materials that are easy to produce and mix), high particle impact speeds, good adhesive strength of the applied layers and, due to the compact size Burner design, the possibility of carrying out an inner coating even with small diameters, has become the most important of all thermal spray processes.

Das Hochgeschwindigkeitsflammspritzen ist ebenfalls am Markt etabliert, ist allerdings für die Zylinderlaufbahnbeschichtung ungeeignet, da hier sehr dichte Schichten aufgebracht werden, die kaum Porositäten aufweisen und häufig im Motorlauf zum Versagen führen. Weiterhin sind Brenner für Innenbeschichtungen noch nicht realisiert.High-speed flame spraying is also well-established on the market, but is unsuitable for cylinder liner coating, since very dense layers are applied here, which have hardly any porosities and often lead to failure in engine operation. Furthermore, burners for interior coatings have not yet been implemented.

Drahtspritzverfahren sind für Zylinderlaufbahnbeschichtungen eine Alternative, allerdings werden hier Schichten erzeugt, die gegenüber den Plasmaspritzschichten eine deutlich geringere Porosität aufweisen und so nach dem Honen nur wenige große Poren an der Laufbahnoberfläche aufweisen, die in den meisten Fällen als Ölrückhaltevolumen unzureichend sind. Ein weiterer Nachteil ist die starke Oxidbildung, insbesondere bei den Eindrahtverfahren (PTWA beziehungsweise RSW), wenn die Schichten ohne Schutzgas gespritzt werden und so zu verstärkter Anfälligkeit gegenüber Korrosion führen können. Diese Oxidbildung führt nicht zu einer durchgehenden Oxidschicht.Wire spraying processes are an alternative for cylinder raceway coatings, however layers are produced here that have a significantly lower porosity compared to plasma spraying layers and thus have only a few large pores on the raceway surface after honing, which in most cases are insufficient as oil retention volumes. Another disadvantage is the strong oxide formation, particularly in the single-wire process (PTWA or RSW), if the layers are sprayed without protective gas and can thus lead to increased susceptibility to corrosion. This oxide formation does not lead to a continuous oxide layer.

Mit besonderem Vorteil umfasst das Verfahren keine Vorbehandlung der Oberfläche des Werkstücks insbesondere keine Aufrauung der Oberfläche des Werkstücks. Das erfindungsgemäße Verfahren schließt die Möglichkeit des Vorbehandelns nicht aus, allerdings ermöglicht das erfindungsgemäße Verfahren, dass die Vorbehandlung der Werkstückoberfläche, insbesondere durch Aufrauung der Werkstückoberfläche, unterbleiben kann. Ein Unterlassen der Vorbehandlung der Oberfläche des Werkstücks, insbesondere ein Unterlassen des Aufrauens der Oberfläche führt neben einer hohen Prozesskosteneinsparung zu einer Verbesserung der Qualität der beschichteten Oberfläche. Ferner können mit dem erfindungsgemäßen Verfahren auch feingespindelte Oberflächen beschichtet werden, wenn eine Vorbehandlung, insbesondere eine Aufrauhung, durch welche die feingespindelte Oberfläche verändert, insbesondere zerstört, werden würde, unterbleibt.The method particularly advantageously does not include any pretreatment of the surface of the workpiece, in particular no roughening of the surface of the workpiece. The method according to the invention does not exclude the possibility of pretreatment, but the method according to the invention enables the pretreatment of the workpiece surface, in particular by roughening the workpiece surface, to be omitted. Failure to pretreat the surface of the workpiece, in particular refraining from roughening the surface, leads not only to high process cost savings, but also to an improvement in the quality of the coated surface. Furthermore, finely spindleed surfaces can also be coated with the method according to the invention if a pretreatment, in particular roughening, by which the finely spindle surface would be changed, in particular destroyed, is omitted.

Das erfindungsgemäße Verfahren weist verschiedene Schritte auf, die aus nachstehender Aufzählung ausgewählt werden können, wobei die oben genannten erfindungswesentlichen Schritte zwingend sind:

  • Gießen eines Zylinderkurbelgehäuses.
  • Zylindrisches Schneiden der beim Gießen resultierenden konischen Gussgeometrie der Zylinderlaufbahn .
  • Feinspindeln der Oberfläche der Zylinderlaufbahn.
  • Waschen und Vakuumtrocknen des Zylinderkurbelgehäuses bei Raumtemperatur.
  • (a) Bereitstellen eines pulverförmigen Basismaterials und eines pulverförmigen Haftvermittlers.
  • (b.1) Unmittelbares Beschichten mit dem Haftvermittler und anschließend mit dem Basismaterial, wobei das Zylinderkurbelgehäuse vorzugsweise fest angeordnet ist und während des Beschichtungsprozesses der Plasmabrenner rotiert und sich entlang der Zylinderlaufbahn in das Zylinderkurbelgehäuse und wieder heraus bewegt, vorzugsweise erfolgt dieser Vorgang einmal um den Haftvermittler aufzutragen und anschließend ein- bis fünfmal, vorzugsweise dreimal um die gewünschte Schichtdicke des Basismaterials aufzutragen, oder wobei die Beschichtung mittels Drahtspritzen erfolgt,
  • oder
  • (b.2) Beschichten mit einem Gemisch aus Haftvermittler und Basismaterial vorzugsweise mittels Plasmapulverspritzen, wobei das Zylinderkurbelgehäuse vorzugsweise fest angeordnet ist und während des Beschichtungsprozesses der Plasmabrenner rotiert und sich entlang der Zylinderlaufbahn in das Zylinderkurbelgehäuse und wieder heraus bewegt, vorzugsweise viermal, wobei dies in Abhängigkeit der gewünschten Schichtdicke variiert werden kann.
  • Beschichten mit dem Basismaterial mittels eines thermischen Beschichtungsverfahrens auf die vorab erzeugte Beschichtung.
  • Fasen an beiden Enden der Zylinderlaufbahn schneiden.
  • Honen auf Maß.
The method according to the invention has various steps which can be selected from the list below, the above-mentioned steps essential to the invention being essential:
  • Casting a cylinder crankcase.
  • Cylindrical cutting of the conical casting geometry of the cylinder race resulting during casting.
  • Fine spindles on the surface of the cylinder race.
  • Wash and vacuum dry the cylinder crankcase at room temperature.
  • (a) Providing a powdery base material and a powdery coupling agent.
  • (b.1) Immediate coating with the adhesion promoter and then with the base material, the cylinder crankcase preferably being fixedly arranged and during the coating process the plasma torch rotating and moving along the cylinder raceway into and out of the cylinder crankcase, preferably this process takes place once around Apply adhesion promoter and then one to five times, preferably three times to apply the desired layer thickness of the base material, or wherein the coating is carried out by wire spraying,
  • or
  • (b.2) Coating with a mixture of adhesion promoter and base material, preferably by means of plasma powder spraying, the cylinder crankcase preferably being fixedly arranged and rotating during the coating process of the plasma torch and moving along the cylinder path into and out of the cylinder crankcase, preferably four times, this in Depending on the desired layer thickness can be varied.
  • Coating with the base material by means of a thermal coating process on the previously generated coating.
  • Cut chamfers on both ends of the cylinder race.
  • Honing to measure.

Der Prozess der thermischen Beschichtung erfolgt vorzugsweise ohne aktive Klimatisierung. Das Zylinderkurbelgehäuse erwärmt sich im Prozess, d.h. während des Beschichtens beispielsweise durch geschmolzenes Plasmapulver und kühlt selbstständig wieder ab. Nach dem Beschichten ist das Zylinderkurbelgehäuse ca. 100°C bis maximal 140°C warm.The thermal coating process is preferably carried out without active air conditioning. The cylinder crankcase heats up in the process, i.e. during the coating process, for example through molten plasma powder and cools down automatically. After coating, the cylinder crankcase is approx. 100 ° C to a maximum of 140 ° C warm.

Vorzugsweise steht das Zylinderkurbelgehäuse für das Beschichten aufrecht und wird auf der Ölwannenseite aufgenommen. Bei der mechanischen Bearbeitung, unter anderem Feinspindeln und Fasenschneiden, wird das Zylinderkurbelgehäuse vorzugsweise am Topdeck aufgenommen. Für die anderen Bearbeitungsschritte kann das Zylinderkurbelgehäuse vorzugsweise auch auf der Getriebeseite aufgenommen werden.The cylinder crankcase is preferably upright for coating and is received on the oil pan side. For mechanical processing, including fine spindles and bevel cutting, the cylinder crankcase is preferably accommodated on the top deck. For the other processing steps, the cylinder crankcase can preferably also be accommodated on the transmission side.

Ein weiterer Aspekt der Erfindung betrifft ein Zylinderkurbelgehäuse mit einer Zylinderlaufbahn, die eine gemäß dem Verfahren der Erfindung hergestellte Beschichtung aufweist.Another aspect of the invention relates to a cylinder crankcase with a cylinder raceway which has a coating produced according to the method of the invention.

Die Beschichtung des erfindungsgemäßen Bauteils weist entweder eine auf einer Oberfläche der Zylinderlaufbahn angeordnete Mischschicht auf, welche das Basismaterial und den Haftvermittler aus Molybdän und Aluminium-haltiger Legierung umfasst. Alternativ umfasst die Beschichtung eine erste Schicht aus dem Haftvermittler und eine zweite Schicht, welche das Basismaterial aber nicht den Haftvermittler umfasst.The coating of the component according to the invention either has a mixed layer arranged on a surface of the cylinder raceway, which comprises the base material and the adhesion promoter made of molybdenum and aluminum-containing alloy. Alternatively, the Coating a first layer of the adhesion promoter and a second layer, which comprises the base material but not the adhesion promoter.

Die Beschichtung verbessert einerseits die Reibfestigkeit der beschichteten Oberfläche stark und weist gleichzeitig eine hohe Beständigkeit auf, da die Beschichtung eine sehr gute Haftung auf der Werkstückoberfläche zeigt. Mit dem erfindungsgemäßen Verfahren werden Haftzugwerte von 50 bis >70 MPa erzielt. Damit werden die Haftzugwerte eines herkömmlichen Prozesses, bei dem die Haftung der Beschichtung durch vorheriges Aufrauen der Oberfläche und ohne Haftvermittler erzielt wird, von 20 bis >70 MPa erreicht und im unteren Bereich sogar überschritten.On the one hand, the coating greatly improves the frictional resistance of the coated surface and at the same time has a high level of resistance, since the coating shows very good adhesion to the workpiece surface. Adhesive tensile values of 50 to> 70 MPa are achieved with the method according to the invention. In this way, the adhesive tensile values of a conventional process, in which the adhesion of the coating is achieved by roughening the surface beforehand and without an adhesion promoter, are achieved from 20 to> 70 MPa and even exceeded in the lower range.

Die erste und die zweite Schicht sind erfindungsgemäß mit einem thermischen Beschichtungsverfahren auf der Werkstückoberfläche aufgebracht.According to the invention, the first and the second layer are applied to the workpiece surface using a thermal coating method.

Ein weiterer Aspekt der Erfindung betrifft einen Motor, welcher ein erfindungsgemäßes Zylinderkurbelgehäuse aufweist.Another aspect of the invention relates to an engine which has a cylinder crankcase according to the invention.

Weitere bevorzugte Ausgestaltungen der Erfindung ergeben sich aus den übrigen, in den Unteransprüchen genannten Merkmalen.Further preferred embodiments of the invention result from the other features mentioned in the subclaims.

Die verschiedenen in dieser Anmeldung genannten Ausführungsformen der Erfindung sind, sofern im Einzelfall nicht anders ausgeführt, mit Vorteil miteinander kombinierbar.The various embodiments of the invention mentioned in this application can be combined with one another with advantage, unless otherwise stated in the individual case.

Die Erfindung wird nachfolgend in Ausführungsbeispielen anhand der zugehörigen Zeichnungen erläutert. Es zeigen:

Figur 1
eine Lichtmikroskop-Aufnahme eines Querschnitts eines beschichteten Werkstücks gemäß einer ersten Ausgestaltung der Erfindung,
Figur 2
eine Lichtmikroskop-Aufnahme eines Querschnitts eines beschichteten Werkstücks gemäß einer zweiten Ausgestaltung der Erfindung,
Figur 3
eine Lichtmikroskop-Aufnahme eines Querschnitts eines beschichteten Werkstücks gemäß einer dritten Ausgestaltung der Erfindung,
Figur 4
eine Lichtmikroskop-Aufnahme eines Querschnitts eines beschichteten Werkstücks gemäß einer vierten Ausgestaltung der Erfindung,
Figur 5
eine Lichtmikroskop-Aufnahme eines Querschnitts eines beschichteten Werkstücks gemäß einer fünften Ausgestaltung der Erfindung, und
Figur 6
eine Lichtmikroskop-Aufnahme eines Querschnitts eines beschichteten Werkstücks gemäß einer sechsten Ausgestaltung der Erfindung.
The invention is explained below in exemplary embodiments with reference to the accompanying drawings. Show it:
Figure 1
1 shows a light microscope image of a cross section of a coated workpiece according to a first embodiment of the invention,
Figure 2
1 shows a light microscope image of a cross section of a coated workpiece according to a second embodiment of the invention,
Figure 3
1 shows a light microscope image of a cross section of a coated workpiece according to a third embodiment of the invention,
Figure 4
1 shows a light microscope image of a cross section of a coated workpiece according to a fourth embodiment of the invention,
Figure 5
a light microscope image of a cross section of a coated workpiece according to a fifth embodiment of the invention, and
Figure 6
a light microscope image of a cross section of a coated workpiece according to a sixth embodiment of the invention.

Die Figuren 1 bis 6 zeigen Lichtmikroskop-Aufnahmen von Querschnitten (Längsschliffe) eines beschichteten Werkstücks 1 (Zylinderlaufbahn) eines Bauteils 10 (Zylinderkurbelgehäuse) in unterschiedlichen Ausführungsformen. Dabei ist ein Teil des Werkstücks 1 gezeigt, auf dessen metallischer Oberfläche eine Beschichtung 2 angeordnet ist. Die Beschichtung 2 kann beispielsweise mit dem erfindungsgemäßen Verfahren aufgebracht werden.The Figures 1 to 6 show light microscope images of cross sections (longitudinal sections) of a coated workpiece 1 (cylinder raceway) of a component 10 (cylinder crankcase) in different embodiments. A part of the workpiece 1 is shown, on the metallic surface of which a coating 2 is arranged. The coating 2 can be applied, for example, using the method according to the invention.

Das in Figur 1 gezeigte Werkstück 1 umfasst eine metallische Oberfläche aus einer Leichtmetalllegierung, genauer einer Aluminium-haltigen Legierung, nämlich AlSi17. Auf dieser Oberfläche wurde in einem Verfahrensschritt die Beschichtung 2 aufgetragen. Die in Figur 2 gezeigte Beschichtung 2 umfasst einen niedrig legierten Stahl als Basismaterial und einen Haftvermittler der in der Schicht integriert ist. Die in Figur 1 gezeigte Beschichtung 2 wurde mit dem erfindungsgemäßen Verfahren erzeugt, indem eine Pulvermischung aus Basismaterial und Haftvermittler mittels Plasmaspritzens auf die metallische Oberfläche aufgebracht wurde. Dabei schmolzen die Partikel der Pulvermischung auf und verbanden sich auf der Oberfläche zu einer einheitlichen Mischschicht 3. Da Basismaterial und Haftvermittler bereits vor bzw. bei dem Prozess des Plasmaspritzens innig vermischt vorlagen, weist das in Figur 1 gezeigte Werkstück 1 eine einschichtige Beschichtung 2 auf, in der der Haftvermittler im Basismaterial im Weitesten homogen verteilt vorliegt und somit einen integrierten Haftgrund bildet.This in Figure 1 The workpiece 1 shown comprises a metallic surface made of a light metal alloy, more precisely an aluminum-containing alloy, namely AlSi 17 . Coating 2 was applied to this surface in one process step. In the Figure 2 Coating 2 shown comprises a low-alloy steel as the base material and an adhesion promoter which is integrated in the layer. In the Figure 1 Coating 2 shown was produced with the method according to the invention in that a powder mixture of base material and adhesion promoter was applied to the metallic surface by means of plasma spraying. The particles of the powder mixture melted and bonded on the surface to form a uniform mixed layer 3. Since the base material and adhesion promoter were intimately mixed before or during the process of plasma spraying, this shows in Figure 1 Workpiece 1 shown on a single-layer coating 2, in which the adhesion promoter is largely homogeneously distributed in the base material and thus forms an integrated primer.

In Figur 2 ist ein Werkstück 1 gezeigt, welches die gleiche Beschichtung 2 wie das in Figur 1 gezeigte Werkstück 1 aufweist. Die Oberfläche des Werkstücks 1 ist allerdings aus Grauguss.In Figure 2 A workpiece 1 is shown which has the same coating 2 as that in FIG Figure 1 workpiece 1 shown. However, the surface of the workpiece 1 is made of gray cast iron.

Die Figuren 3 und 4 zeigen je eine Lichtmikroskop-Aufnahme eines Querschnitts (Längsschliff) eines beschichteten Werkstücks 1 gemäß einer weiteren Ausgestaltung der Erfindung. Die Figuren 3 und 4 zeigen jeweils ein Werkstück 1 mit einer zweischichtigen Beschichtung 2. Die Beschichtung 2 umfasst hier eine Mischschicht 3, die eine Mischung aus dem Basismaterial und dem Haftvermittler umfasst. Die Mischschicht 3 entspricht im Wesentlichen der Mischschicht 3 der in den Figuren 1 und 2 gezeigten Ausführung, ist aber im Unterschied zu dieser Schichtdicken zwischen 20 und 55 µm deutlich dünner ausgeführt. Auf die Mischschicht 3 aus Basismaterial und Haftvermittler ist eine Basismaterialschicht 4 angeordnet, die im Wesentlichen aus dem Basismaterial besteht. Diese ist um ein Vielfaches dicker als die Mischschicht 3. Bevorzugte Schichtdicken liegen bei Pulverplasmaspritzschichten im Bereich von 120 bis 180 µm, insbesondere im Bereich von 140 bis 160 µm und maximal bei 300 µm, und bei Drahtspritzschichten bevorzugt im Bereich von 150 bis 300 µm, insbesondere im Bereich von 170 bis 250 µm, bis maximal 500 µm. Die Mischschicht 3 hat die Funktion, die Haftung der Beschichtung 2 zu erhöhen, während die Basismaterialschicht 4 die Eigenschaften des Werkstücks nach außen, wie beispielsweise die Reibfestigkeit, bestimmt. Die Figuren 3 und 4 unterscheiden sich in dem Material des beschichteten Werkstücks. Während die Beschichtung 2 in Figur 3 auf einer Leichtmetalllegierung, beispielsweise einer Aluminium-haltigen Legierung wie AlSi17, angeordnet ist, handelt es sich bei dem Material des Werkstücks 1 der in Figur 4 gezeigten Ausführung um einen Grauguss.The Figures 3 and 4 each show a light microscope image of a cross section (longitudinal section) of a coated workpiece 1 according to a further embodiment of the invention. The Figures 3 and 4 each show a workpiece 1 with a two-layer coating 2. The coating 2 here comprises a mixed layer 3, which comprises a mixture of the base material and the adhesion promoter. The mixed layer 3 essentially corresponds to the mixed layer 3 the one in the Figures 1 and 2 shown execution, but is in contrast to this layer thickness between 20 and 55 microns much thinner. A base material layer 4, which essentially consists of the base material, is arranged on the mixed layer 3 composed of base material and adhesion promoter. This is many times thicker than the mixed layer 3. Preferred layer thicknesses for powder plasma spray layers are in the range from 120 to 180 μm, in particular in the range from 140 to 160 μm and at most 300 μm, and in the case of wire spray layers preferably in the range from 150 to 300 μm, especially in the range from 170 to 250 µm, up to a maximum of 500 µm. The mixed layer 3 has the function of increasing the adhesion of the coating 2, while the base material layer 4 determines the properties of the workpiece to the outside, such as the frictional resistance. The Figures 3 and 4 differ in the material of the coated workpiece. While the coating is 2 in Figure 3 is arranged on a light metal alloy, for example an aluminum-containing alloy such as AlSi 17 , the material of the workpiece 1 in FIG Figure 4 shown execution around a gray cast iron.

Die in den Figuren 3 und 4 gezeigten Beschichtungen 2 können mit dem erfindungsgemäßen Verfahren aufgebracht werden. Dazu wird zunächst eine Pulvermischung aus Haftvermittler und Basismaterial bereitgestellt und mittels eines thermischen Beschichtungsverfahrens, wie Plasmaspritzen, auf der Oberfläche des Werkstücks 1 angeordnet, so dass eine homogene Mischschicht 3 entsteht. Anschließend wird ein Pulver, welches das Basismaterial aber nicht den Haftvermittler enthält bereitgestellt und ebenfalls mit einem, vorzugsweise dem gleichen, thermischen Verfahren auf die Mischschicht 3 aufgetragen. Zu einer einfachen Realisierung kann die Vorrichtung, die das thermische Beschichtungsverfahren ausführt mit einem Doppelpulverförderer ausgestattet sein, so dass die selbe Vorrichtung für beide Beschichtungsschritte verwendet werden kann.The in the Figures 3 and 4 The coatings 2 shown can be applied using the method according to the invention. For this purpose, a powder mixture of adhesion promoter and base material is first provided and arranged on the surface of the workpiece 1 by means of a thermal coating process, such as plasma spraying, so that a homogeneous mixing layer 3 is formed. A powder which contains the base material but not the adhesion promoter is then provided and is likewise applied to the mixing layer 3 using a, preferably the same, thermal method. For a simple implementation, the device that carries out the thermal coating process can be equipped with a double powder conveyor, so that the same device can be used for both coating steps.

Die Figuren 5 und 6 zeigen ebenfalls je eine Lichtmikroskop-Aufnahme eines Querschnitts (Längsschliff) eines beschichteten Werkstücks 1 gemäß weiterer Ausgestaltungen der Erfindung. Die Figuren 5 und 6 zeigen die gleiche Beschichtung 2, unterscheiden sich jedoch in dem Material des Werkstücks 1, die in Figur 5 eine Leichtmetalllegierung (insbesondere AlSi17) und im Werkstück 1 der Figur 6 einen Grauguss umfasst. Die Beschichtung 2 der in den Figuren 5 und 6 gezeigten Ausführungsform ist ebenfalls als zweischichtiges System ausgebildet, wobei die erste an der Werkstückoberfläche angeordnete Schicht ein Haftgrund 5 ist auf dem eine Basismaterialschicht 6 abgeschieden ist, die das Basismaterial enthält. In dieser Ausführungsform weist der Haftgrund 5 den Haftvermittler auf und enthält kein Basismaterial.The Figures 5 and 6 each show a light microscope image of a cross section (longitudinal section) of a coated workpiece 1 according to further embodiments of the invention. The Figures 5 and 6 show the same coating 2, but differ in the material of the workpiece 1, which in Figure 5 a light metal alloy (in particular AlSi 17 ) and in the workpiece 1 Figure 6 includes a gray cast iron. The coating 2 in the Figures 5 and 6 The embodiment shown is also designed as a two-layer system, the first layer arranged on the workpiece surface being an adhesive base 5 on which a base material layer 6 is deposited, which contains the base material. In this embodiment, the primer 5 has the adhesion promoter and contains no base material.

Das Basismaterial der gezeigten Ausführungsformen ist ein niedriglegierter Stahl, wie beispielsweise (vorzugsweise eisenbasierter Stahl mit 0,05 bis 1.5 Gew.-% Kohlenstoff; 0,05 bis 3.5 Gew.-% Mangan; 0.05 bis 3,0 Gew.-% Chrom; 0,01 bis 1 Gew.-% Silizium und/oder 0,001 bis 0,4 Gew.-% Schwefel und/oder einen Chromstahl mit einer Eisenbasis und 0,05 bis 0.8 Gew.-% Kohlenstoff; 0 - 3 Gew.-% Molybdän; 0,05 bis 1.8 Gew.-% Mangan; 11.5 bis 18 Gew-% Chrom ; 0,01 bis 1 Gew.-% Silizium und/oder 0,002 bis 0,2 Gew.-% Schwefel. Das Verhältnis aus Haftvermittler und Basismaterial weist in den Mischschichten 3 der Figuren 1 bis 4 vorzugsweise ein Verhältnis von 20 Gew.-% Haftvermittler zu 80 Gew.-% Basismaterial auf. Prinzipiell ist der Haftvermittler in einem Bereich von 10 bis 80 Gew.-% und das Basismaterial entsprechend im Bereich von 20 bis 90 Gew.-% in der Mischschicht 3 enthalten.The base material of the embodiments shown is a low-alloy steel, such as (preferably iron-based steel with 0.05 to 1.5% by weight of carbon; 0.05 to 3.5% by weight of manganese; 0.05 to 3.0% by weight of chromium; 0.01 to 1% by weight silicon and / or 0.001 to 0.4% by weight sulfur and / or a chrome steel with an iron base and 0.05 to 0.8% by weight carbon; 0 - 3% by weight Molybdenum; 0.05 to 1.8% by weight manganese; 11.5 to 18% by weight chromium; 0.01 to 1% by weight silicon and / or 0.002 to 0.2% by weight sulfur. The ratio of adhesion promoter and Base material has in the mixed layers 3 of the Figures 1 to 4 preferably a ratio of 20% by weight of adhesion promoter to 80% by weight of base material. In principle, the adhesion promoter is contained in the mixed layer 3 in a range from 10 to 80% by weight and the base material accordingly in the range from 20 to 90% by weight.

Der Haftvermittler ist in allen gezeigten Ausführungsformen eine Mischung aus Molybdän und einer Ni5Al-Legierung (95% Nickel % und 5% Aluminium) oder eine Mischung aus Molybdän NiAI-Legierung und dem Basismaterial wie oben beschrieben. Alternativ kann Nickel in der Aluminium-haltigen Legierung durch Kobalt, Kupfer oder Silber ersetzt werden. Dabei ist Molybdän zu 20 bis 80 Gew.-% und die Aluminium-haltige Legierung in einem Bereich von 20 bis 80 Gew.-% im Haftvermittler enthalten.In all of the embodiments shown, the adhesion promoter is a mixture of molybdenum and a Ni5Al alloy (95% nickel% and 5% aluminum) or a mixture of molybdenum NiAI alloy and the base material as described above. Alternatively, nickel in the aluminum-containing alloy can be replaced by cobalt, copper or silver. Molybdenum is 20 to 80 wt .-% and the aluminum-containing alloy in a range of 20 to 80 wt .-% in the coupling agent.

Alternativ oder zusätzlich sind derartige Schichten auch mittels Drahtspritzverfahren wie LDS, PTWA und RSW darstellbar, indem der Haftvermittler in einem Fülldraht positioniert wird oder indem Drahtspritzschichten auf einen durch ein Plasmaspritzverfahren aufgebrachten Haftgrund gespritzt werden können.As an alternative or in addition, layers of this type can also be produced by means of wire spray processes such as LDS, PTWA and RSW, in that the adhesion promoter is positioned in a cored wire or in that wire spray layers can be sprayed onto an adhesive base applied by a plasma spray process.

BezugszeichenlisteReference list

1010th
Bauteil (Zylinderkurbelgehäuse)Component (cylinder crankcase)
11
Werkstück (Zylinderlaufbahn)Workpiece (cylinder race)
22nd
BeschichtungCoating
33rd
Mischschicht aus Basismaterial und HaftvermittlerMixing layer of base material and adhesion promoter
44th
BasismaterialschichtBase material layer
55
Haftgrund / erste SchichtPrimer / first layer
66
Basismaterialschicht / zweite SchichtBase material layer / second layer

Claims (10)

  1. Process for coating a cylinder working surface (1) consisting of grey cast iron or an aluminium-containing lightweight metal alloy of a cylinder crankcase (10), comprising the steps
    (a) provision of a pulverulent base material, where the base material is iron or an iron alloy, and provision of a pulverulent bonding agent, where the bonding agent comprises a mixture of:
    from 20 to 80% by weight of molybdenum (Mo),
    from 20 to 80% by weight of an aluminium-containing alloy selected from among a nickel-aluminium alloy, a copper-aluminium alloy, a cobalt-aluminium alloy, a magnesium-cobalt-aluminium alloy, a silicon-aluminium alloy, a silver-aluminium alloy and an aluminium bronze, and
    optionally from 0.2 to 5% by weight of boron, in each case based on the bonding agent, where the molybdenum, the aluminium-containing alloy and boron add up to 100% by weight, and
    (b) application of the base material and the bonding agent to the cylinder working surface (1) of the cylinder crankcase (10) by means of a thermal coating process, either
    - by application of a layer (3) or a powder mixture composed of the bonding agent and the base material, or
    - application of a first layer (5) comprising the bonding agent and subsequently application of a second layer (6) comprising the base material on top of the first layer (5).
  2. Process according to Claim 1, characterized in that the base material comprises steel.
  3. Process according to either of the preceding claims, characterized in that the bonding agent and the base material are present in a weight ratio of 10/90, 20/80, 30/70, 40/60 or 50/50 in the powder mixture.
  4. Process according to any of the preceding claims, characterized in that step (b) comprises application of a layer (3) of a powder mixture composed of the bonding agent and base material and the process comprises a further step (c) in which a layer (4) of the base material is applied by means of a thermal coating process to the coating produced in step (b).
  5. Process according to any of the preceding claims, characterized in that the bonding agent comprises Ni(95%)Al(5%).
  6. Process according to any of the preceding claims, characterized in that the thermal coating process is plasma spraying.
  7. Process according to any of the preceding claims, characterized in that the thermal coating process is wire spraying and step (b) is followed by application of the base material and the bonding agent by application of a first layer (5) comprising the bonding agent and subsequent application of a second layer (6) comprising the base material on top of the first layer (5).
  8. Process according to any of the preceding claims, characterized in that the process does not comprise any roughening of the cylinder working surface (1) of the cylinder crankcase (10).
  9. Cylinder crankcase (10) having a cylinder working surface (1) which comprises a coating (2) applied by means of a process according to any of Claims 1 to 8.
  10. Engine comprising a cylinder crankcase (10) according to Claim 9.
EP16730300.7A 2015-07-23 2016-06-08 Method for coating a cylinder barrel of a cylinder crankcase, cylinder crankcase with a coated cylinder barrel and engine Active EP3325685B1 (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
DE102015213896.8A DE102015213896A1 (en) 2015-07-23 2015-07-23 Process for coating a metallic tool and component
PCT/EP2016/063060 WO2017012769A1 (en) 2015-07-23 2016-06-08 Method for coating a cylinder barrel of a cylinder crankcase, cylinder crankcase with a coated cylinder barrel and engine

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EP3325685A1 EP3325685A1 (en) 2018-05-30
EP3325685B1 true EP3325685B1 (en) 2020-04-08

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CN (1) CN107810290B (en)
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CN114672759A (en) * 2022-04-08 2022-06-28 中国人民解放军第五七一九工厂 Aluminum alloy wear surface size repairing method

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CN107810290B (en) 2019-12-20
WO2017012769A1 (en) 2017-01-26
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CN107810290A (en) 2018-03-16
DE102015213896A1 (en) 2017-01-26

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