EP3344801A1

EP3344801A1 - Improved method for forming a pipe lining of a cylinder head and cylinder head thus obtained

Info

Publication number: EP3344801A1
Application number: EP16762776.9A
Authority: EP
Inventors: Patrick KÉRAMPRAN; Denis Massinon
Original assignee: Sifco Applied Surface Concepts; Montupet SA
Current assignee: Sifco Applied Surface Concepts; Montupet SA
Priority date: 2015-09-03
Filing date: 2016-09-05
Publication date: 2018-07-11
Also published as: MX2018002736A; KR20180081039A; CN108368633A; CA2997386A1; US20180252180A1; WO2017037303A1; JP2018527516A; FR3040712B1; FR3040712A1

Abstract

The invention relates to a method for forming a lining on the walls of an inner pipe of a cast aluminium-alloy part, including inserting a cathode into the pipe, circulating an electrolyte solution in said pipe between the cathode and the walls of the pipe forming an anode, and applying a potential difference between the anode and the cathode, the method being characterised in that applying the potential difference between the anode and the cathode includes applying a series of DC voltage pulses to the anode. The invention also relates to a cylinder head in which the exhaust pipes are lined with a lining obtained by implementing said method.

Description

IMPROVED METHOD OF FORMING A COIL CONDUIT COATING

HEAD AND CYLINDER HEAD SO OBTAINED

FIELD OF THE INVENTION

The invention relates to a process for forming an aluminum oxide coating on the walls of an aluminum alloy automobile head, and an automobile cylinder head obtained by such a method. STATE OF THE ART

The cylinder heads are made of aluminum alloy mainly for reasons of weight gain. The increase in the specific power of recently developed engines imposes on the cylinder head increasingly high thermal loads.

The good cooling of the cylinder head is obtained by the integration of cooling circuits inside it, more and more complex, made during the molding of the cylinder head by sand cores.

This makes it possible, to a certain extent, to compensate for the rise in temperature generated by the increase in specific power of the engine, but proves to be more and more often insufficient, and moreover it is necessary to modify the geometry of the interior ducts of the cylinder heads.

To further limit the temperature rise of the cylinder head, it has been proposed electrochemical processes for forming, on the interior duct walls of the cylinder heads, for example exhaust ducts, an oxide coating, in order to limit the heat exchanges between the cylinder head and the duct (for example the exhaust gases present in the duct).

This makes it possible on the one hand to reduce the temperature of the cylinder head and, on the other hand, to increase the temperature of the gases at the outlet of the cylinder head, which improves the efficiency of the engine, without impacting the geometry of the pipes.

For example, document WO 2013/38249 describes such a process for anodic oxidation of the walls of exhaust ducts of a cylinder head.

However, this method has the disadvantage that the coating thus obtained is porous because of the dissolution of the aluminum during the electrolysis. The presence of these porosities can generate crack primers in particular when the cylinder head is exposed to the usual operating temperatures of the engine, which can reach 250 ° C or more.

This can result in leaks between the water or coolant circuits in the immediate vicinity of the exhaust ducts to these ducts, which can lead to engine failure.

It is therefore necessary to carry out a post-treatment clogging of the oxide coating, which makes the process longer and more expensive.

Furthermore, it is known from JP3944788 a process for coating internal conduit cylinder revolution. The treatment disclosed by this document is presented as allowing to confer on the inner surface of the cylinder good abrasion resistance while ensuring good lubrication. The oxide layer thus formed does not limit the heat exchange between the inside of the duct and the walls. Moreover, the teaching of this document is limited to the processing of a cylinder of extremely simple geometry, and the processing of complex geometries is not considered.

Document US 2013/0146041 describes another method, which does not mention the application of DC voltage pulses.

The method disclosed by this document is also limited to a simple cylinder geometry. In document JP3944788 as in document US 2013/0146041, the surface to be coated thus extends around a unit volume.

In the present text, and as illustrated in FIG. A, a unit volume is defined as a volume in which any segment linking in a straight line two points M and N of the volume fully belongs to this volume (in other words: for any pair of points (M, N) of the volume, any point of the segment linking these two points in a straight line also belongs to said volume). A complex volume with ramifications is thus not unitary.

The methods described in JP3944788 and US 2013/0146041 would therefore not be applicable to complex geometries, including cylinder head.

These processes are also not likely to give access to aluminum oxide layers of low porosity, and thin.

There is therefore a need for a solution to limit the heat exchange between the exhaust and the cylinder head does not have these disadvantages. PRESENTATION OF THE INVENTION

The object of the invention is to propose a process for forming an oxide coating in internal cylinder head ducts that do not have the drawbacks of the prior art.

In particular, an object of the invention is to allow the formation of an oxide coating that does not require post-treatment clogging.

Another object of the invention is to provide a method of forming an oxide coating to obtain an improved quality of oxide relative to the prior art.

Another object of the invention is to provide a process for forming an oxide coating faster implementation compared to the prior art, compatible with mass production.

In this regard, the subject of the invention is a process for forming an oxide coating on walls of an inner duct of an aluminum alloy casting, comprising the insertion of a cathode into the duct. , circulating an electrolytic solution in said conduit between the cathode and the walls of the anode conduit, and applying a potential difference between the anode and the cathode,

the method being characterized in that the application of the potential difference between the anode and the cathode comprises applying a series of DC voltage pulses to the anode.

Advantageously, but optionally, the method according to the invention may further comprise at least one of the following characteristics:

each pulse of the series has a duration between 0.01 and 0.02 s and two successive pulses are separated from 0.001 to 0.01 s.

the voltage applied to the anode varies during the series of pulses and is between 0 and 150 V to maintain a current density of between 10 and 50 A dm ² of surface to be treated.

the total duration of the series of pulses is between 30 and 300 s depending on the type of alloy to be treated and the desired oxide thickness, the electrolyte comprises 10 to 20% of sulfuric acid and 1 to 5% ferrous sulphate. the flow of electrolyte in a conduit is between 0.5 and 2.0 m ³ / h per dm ² of surface to be treated.

the temperature of the electrolyte in a conduit is between -10 ° C and 0 ° C.

- The cathode is shaped to conform to the shape of the internal duct or ducts of the casting, leaving a mean gap between 3 and 15 mm between the cathode and the duct wall.

The subject of the invention is also an aluminum alloy automobile cylinder head, characterized in that it comprises, on the walls of at least one internal duct, an aluminum oxide coating having a thickness of between 50 and 200 μηι, adapted to ensure the sealing and thermal insulation of the wall of the internal duct of the cylinder head during the flow, in said duct, exhaust gas at a temperature above 900 ° C.

Advantageously, the breech is obtained by implementing the method according to the foregoing description.

In one embodiment, the internal conduits of the cylinder head provided with an oxide coating are exhaust pipes of combustion products.

The use of pulsed currents during the anodizing treatment of the cylinder head makes it possible to obtain a coating of a predetermined thickness more rapidly.

In addition, the pulsed streams also provide a coating of increased quality and non-porous. This coating thus makes it possible to seal the ducts of the cylinder head, which eliminates the need for a post-treatment clogging.

The use of a cathode whose geometry is consistent with that of the internal duct of the cylinder head to be coated allows to generate homogeneous streamlines on the entire duct and thus a coating of uniform thickness at the end of the treatment. It should be noted that the geometry of the internal cylinder head ducts is complex, as shown in FIG. 6. In this sectional figure, the presence of multiple branches from a base opening opening into the combustion chamber (no shown). Each branch extends from this base with different curvatures according to their distance to the axis of symmetry XX of the structure, passing through the base opening. It is therefore clear from this illustration that obtaining a coating of uniform thickness throughout the duct requires a treatment process that ensures homogeneous current lines at all times. The method according to the invention meets these needs.

The choice of the composition of the electrolyte contributes to the reduction of the porous character of the coating and thus contributes to its sealing character.

The modulation of the electrolyte flow also makes it possible to evacuate at best the calories generated (Joule losses) during the electrolysis in order to limit the phenomenon of dissolution of the oxide layer occurring during the generation of this layer. Maintaining the electrolyte temperature in the desired range improves the quality of the resulting coating layer.

DESCRIPTION OF THE FIGURES

Other characteristics, objects and advantages of the invention will emerge from the description which follows, which is purely illustrative and nonlimiting, and which should be read with reference to the appended drawings in which, in addition to FIG. unitary:

Figure 1 schematically a system for implementing a method of forming a coating on a cylinder head according to an embodiment of the invention.

Figure 2a shows internal ducts of a cylinder head, and Figure 2b shows an integrated exhaust manifold cylinder head. Figure 3 shows a cathode shaped to correspond to the shape of the internal ducts of a cylinder head.

FIG. 4 represents the evolution of the voltage applied to the cylinder head and the current density between the anode and the cathode during the implementation of the insulating coating formation process.

FIG. 5 represents an EDS analysis spectrum of the aluminum oxide deposited by the process.

Figure 6 is a sectional illustration of the geometry of an internal automobile cylinder head for which the method of forming a coating according to the invention is suitable. FIG. 7a illustrates a section of thickness observation of the anodizing layer

Figure 7b illustrates another thickness observation section of the anodizing layer.

DETAILED DESCRIPTION OF AT LEAST ONE MODE OF IMPLEMENTING THE INVENTION

Referring to Figure 1, there is shown schematically a casting part 10 of aluminum alloy. This casting piece is of complex geometry and includes internal conduits 1 1 embedded.

The constituent alloy of this casting is based on aluminum-silicon hypo-eutectic type, comprising less than 12.5% silicon by mass, and may contain alloying elements such as copper and magnesium .

By way of non-limiting example, the constituent alloy of this part 10 may be AA319 or an AA356 type alloy.

As shown in FIG. 2, the casting is advantageously a motor yoke 10. In this case, the internal ducts 1 1 considered are advantageously exhaust ducts of combustion products. In this respect, the cylinder head 10 is advantageously a cylinder head comprising an integrated exhaust gas manifold, as is the case, for example, of the cylinder head of FIG. 2b. In Figure 2b are also shown the combustion chambers 19 of the cylinder head.

In order to limit the heat exchange between the exhaust gases flowing in the duct 11, whose temperature may exceed 900 ° C., and the piece 10, a method of forming an insulating coating 13 is implemented. aluminum oxide on the inner walls of each pipe 1 1 by anodic oxidation.

The system 1 used to implement this method is shown in FIG.

It comprises a cathode 3 disposed inside the cylinder head, a circuit 2 for circulating an electrolytic solution between the cathode and the walls of the ducts of the anode cylinder head, and a control circuit 4 for controlling the potential difference imposed. between the anode and the cathode, said potential difference generating the oxidation reaction at the anode forming the oxide coating. Electrolytic solution circulation system

The circulation system 2 of the electrolytic solution in the ducts 1 1 of the cylinder head is shown in FIG. It advantageously comprises an electrolytic solution tank 20, a pump 21, and a closed circuit 22 for circulating the solution between the reservoir and the ducts 1 1 of the cylinder head. The electrolyte solution preferably comprises between 10 and 20% sulfuric acid and 1 to 5% ferrous sulfate.

To avoid dissolution of the oxide created during the coating forming process, this dissolution being catalysed by the heat caused by the electrolysis, the solution is advantageously maintained at a temperature between -10 ° C and 0 ° C.

In this respect, the circuit 2 advantageously comprises a cooling member 23 of the electrolytic solution. In addition, the pump is advantageously variable flow to modulate the flow of electrolyte as a function of temperature.

Advantageously, the pump 21 is sized according to the surface to be coated and the thickness of the oxide layer to be grown, and is advantageously adapted to circulate a flow of electrolytic solution in the cylinder head between 0.5 and 2 m ³ per hour and per square decimeter (/ hr dm ² ) of surface to be treated.

The circulation of electrolyte in the ducts at a temperature between -10 and 0 ° C makes it possible to obtain a homogeneous coating. Cathode layout

A cathode 3 is positioned inside the exhaust ducts 1 1 of the cylinder head. This cathode is made of a material allowing oxidation-reduction reactions to occur in the electrolytic solution. In particular, the cathode is advantageously made of stainless steel type 316L for example.

Referring to Figure 3, the cathode 3 is advantageously shaped so as to match the shape of the ducts 1 1 leaving a gap, preferably constant, between the cathode and the ducts, allowing the circulation of the electrolyte. This makes it possible to establish, when applying a potential difference between the anode and the cathode, current lines homogeneous over an entire surface to be coated, and thus to obtain a growth rate of the identical layer on the surface. This makes it possible to obtain at the end of the process a homogeneous layer thickness on all the treated surfaces.

The average gap between the cathode and the wall of a duct is advantageously between 3 and 15 mm. This is a good compromise on the thickness to be maintained between the cathode and the wall of the duct 1 1, firstly to promote the circulation of the electrolyte and the entrainment of the gases generated during the electrolysis, including when the oxide layer has begun to form, and secondly to maintain a current density sufficient to not slow down the growth of the oxide layer.

Anodal oxidation

Returning to FIG. 1, the system for implementing the process for forming a coating layer on the ducts of the cylinder head 10 further comprises a circuit 4 for controlling the potential difference between the anode and the cathode.

The circuit 4 comprises a voltage source 40, adapted to deliver a voltage to the anode forming head 10, a control unit 41 of the voltage source, and one or more sensors (not shown) adapted to detect the voltages between the voltage source. anode and the cathode, as well as the current between the anode and the cathode to obtain the defined current.

With reference to FIG. 4, to form the oxide layer 13 on the walls of the conduits 1 1, the control unit 41 drives the voltage source 40 to deliver a series of DC voltage pulses to the anode.

The frequency of the voltage pulses is advantageously greater than 10 Hz, preferably between 10 and 50 Hz.

More specifically, each voltage pulse has a duration of less than 0.1 seconds, and preferably between 0.01 and 0.02 seconds, during which the value of the voltage applied to the anode is constant. Each pulse is further separated from the next pulse by a non-zero time interval of less than 0.1 second, preferably less than 0.01 second, and advantageously between 0.001 and 0.01 second. During this time interval, the voltage applied to the anode is zero. The application of such a series of voltage pulses makes it possible to reduce the time required to implement the process by promoting the evacuation of Joule losses and gases.

By way of comparison, obtaining an oxide layer with a thickness of between 50 and 200 μηη requires a processing time of the order of 70 seconds, whereas the time required in the prior art was order of several minutes.

In addition, the values of the voltage of each pulse gradually change as the formation of the oxide layer. Indeed, because of its insulating nature, the oxide layer opposes establishing a current between the anode and the cathode.

In particular, the control of the voltage source 40 by the control unit 41 is slaved to the value of the current density between the anode and the cathode. The measurement of the current by the sensors enables the control unit 41 to calculate the current density and, depending on the result, to control the value of the voltage delivered by the voltage source 40.

To maintain a current density sufficient to continue the growth of the layer, the voltage is generally increasing on the series of pulses. The desired current density is advantageously between 5 and 50 A dm ² of surface to be treated.

Thus the value of the voltage of each pulse is between 0 and

150 V, advantageously between 0 and 120 V, the pulses occurring in the first seconds, for example the first 5 or 10 seconds, of the process having a voltage of between 0 and 50 V, and the following pulses advantageously having an increasing voltage up to to reach a voltage sufficient to maintain a current density advantageously greater than 5 A / dm ² , preferably greater than 10 A / dm ² . This maximum voltage is advantageously between 70 and 150 V, and preferably between 70 and 120 V.

This series of continuous voltage pulses at the anode is implemented for a period of between 30 and 300 s depending on the type of alloy to be treated and the thickness of the oxide layer that is desired get.

Thus the application of a potential at the anode generates a potential difference between the cylinder head and the cathode, at the origin of chemical reactions producing, from the aluminum of the cylinder head, an aluminum oxide on the Exhaust duct walls 1 1. There is shown in Figure 5 an EDS (Energy Dispersive Spectroscopy) analysis spectrum produced on the aluminum oxide thus produced. The relative heights of the peaks of this spectrum indicate a composition of the oxide near stoichiometric that of Al ₂ O ₃ alumina, the other components being pollutants from the electrolytic composition.

So that the oxide layer 13 ensures the insulation of the cylinder head in operation, that is to say when gases with a temperature of 950 ° C flow in the internal conduits, the formed oxide layer each inner duct advantageously has a thickness advantageously between 50 and 200μη "ΐ This thickness varies mainly as a function of the silicon and copper concentration of the treated aluminum alloy, but it remains fine enough not to modify the dimensional characteristics of the product within a tolerance range of ± 0.5 mm.

It has been demonstrated that the application of a heat treatment of the T7 type, that is to say comprising a dissolution at a temperature of between 490 and 540 ° C. (depending on the alloy of aluminum used), quenching with water or air, and tempering at a temperature equal to or greater than 200 ° C, made it possible to obtain more homogeneous coating layers in thickness and density.

By way of illustration and in a nonlimiting manner, FIGS. 7a and 7b show a sectional view of an oxide coating on a cylinder head obtained as a result of a treatment according to a method according to the invention. In these illustrations, the oxide layer is between 34.92 μηη and 70.32 μηη and has a maximum porosity of 15%. Porosity is understood to mean a global void ratio within the oxide layer.

This gives a good layer density on the one hand and a small thickness on the other hand. Thus, it is no longer necessary to perform subsequent sealing treatment, or recovery or finishing machining. Moreover, the process thus described leads to cycle times compatible with industrial mass production in the automotive sector (ie 5 to 6 minutes).

The proposed method thus makes it possible to obtain, in a reduced time, an insulating coating of uniform thickness on internal ducts of aluminum alloy parts such as automobile heads.

Claims

1. A method of forming an aluminum oxide coating on walls of an inner duct (1 1) of an aluminum alloy casting (10), the method comprising inserting a cathode (3) ) in the conduit (1 1), the circulation of an electrolytic solution in said conduit between the cathode (3) and the walls of the duct (1 1) forming anode, and the application of a potential difference between the anode and the cathode,

2. Training method according to claim 1, characterized in that each pulse of the series has a duration between 0.01 and 0.02 s and two successive pulses are separated from 0.001 to 0.01 s.

3. Training method according to one of claims 1 or 2, characterized in that the voltage applied to the anode varies during the series of pulses, and is between 0 and 150 V to maintain a current density included between 10 and 50 A dm ² of surface to be treated.

4. Formation method according to one of claims 1 to 3, characterized in that the total duration of the series of pulses is between 30 and 300 s depending on the type of alloy to be treated and the thickness of the desired oxide.

5. Formation process according to one of claims 1 to 4, characterized in that the electrolyte comprises 10 to 20% sulfuric acid and 1 to 5% ferrous sulfate.

6. The forming method according to one of claims 1 to 5, wherein the flow of electrolyte in a conduit is between 0.5 and 2.0 m ³ / h per dm ² of surface to be treated.

7. The forming method according to one of claims 1 to 6 wherein the temperature of the electrolyte in a conduit is between -10 ° C and 0 ° C.

8. Training method according to one of the preceding claims characterized in that the cathode (3) is shaped to conform to the shape of the internal duct (s) (1 1) of the casting (10), leaving an average gap between 3 and 15 mm between the cathode and the duct wall.

Automotive cylinder head (10) made of aluminum alloy, characterized in that it comprises, on the walls of at least one inner pipe (1 1), a coating (13) of aluminum oxide of a thickness between 50 and 200 μηι, adapted for sealing and thermal insulation of the wall of the internal duct of the cylinder head during the flow, in said duct, of exhaust gas at a temperature greater than 900 ° C .

10. Cylinder head (10) according to claim 9, the yoke being obtained by the implementation of the method according to one of claims 1 to 8.

1 1. The automobile cylinder head (10) according to one of claims 9 or 10, wherein the inner conduits (1 1) provided with a coating (13) of oxide are exhaust pipes of combustion products.