GB2106433A - Squeeze casting of pistons - Google Patents

Squeeze casting of pistons Download PDF

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Publication number
GB2106433A
GB2106433A GB08128674A GB8128674A GB2106433A GB 2106433 A GB2106433 A GB 2106433A GB 08128674 A GB08128674 A GB 08128674A GB 8128674 A GB8128674 A GB 8128674A GB 2106433 A GB2106433 A GB 2106433A
Authority
GB
United Kingdom
Prior art keywords
whiskers
piston
fibres
mat
mould
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Granted
Application number
GB08128674A
Other versions
GB2106433B (en
Inventor
Roger Anthony Day
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
AE PLC
Original Assignee
AE PLC
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by AE PLC filed Critical AE PLC
Priority to GB08128674A priority Critical patent/GB2106433B/en
Priority to DE19823234504 priority patent/DE3234504A1/en
Priority to FR8215983A priority patent/FR2513153B1/en
Priority to JP57165968A priority patent/JPS58100642A/en
Priority to IT46860/82A priority patent/IT1159218B/en
Publication of GB2106433A publication Critical patent/GB2106433A/en
Application granted granted Critical
Publication of GB2106433B publication Critical patent/GB2106433B/en
Expired legal-status Critical Current

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Classifications

    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22DCASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D19/00Casting in, on, or around objects which form part of the product
    • B22D19/0009Cylinders, pistons
    • B22D19/0027Cylinders, pistons pistons
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22DCASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D19/00Casting in, on, or around objects which form part of the product
    • B22D19/14Casting in, on, or around objects which form part of the product the objects being filamentary or particulate in form
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F02COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
    • F02FCYLINDERS, PISTONS OR CASINGS, FOR COMBUSTION ENGINES; ARRANGEMENTS OF SEALINGS IN COMBUSTION ENGINES
    • F02F3/00Pistons 
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F02COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
    • F02FCYLINDERS, PISTONS OR CASINGS, FOR COMBUSTION ENGINES; ARRANGEMENTS OF SEALINGS IN COMBUSTION ENGINES
    • F02F3/00Pistons 
    • F02F3/10Pistons  having surface coverings
    • F02F3/12Pistons  having surface coverings on piston heads
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F02COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
    • F02FCYLINDERS, PISTONS OR CASINGS, FOR COMBUSTION ENGINES; ARRANGEMENTS OF SEALINGS IN COMBUSTION ENGINES
    • F02F2200/00Manufacturing
    • F02F2200/06Casting
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F05INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
    • F05CINDEXING SCHEME RELATING TO MATERIALS, MATERIAL PROPERTIES OR MATERIAL CHARACTERISTICS FOR MACHINES, ENGINES OR PUMPS OTHER THAN NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES
    • F05C2201/00Metals
    • F05C2201/02Light metals
    • F05C2201/021Aluminium
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F05INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
    • F05CINDEXING SCHEME RELATING TO MATERIALS, MATERIAL PROPERTIES OR MATERIAL CHARACTERISTICS FOR MACHINES, ENGINES OR PUMPS OTHER THAN NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES
    • F05C2201/00Metals
    • F05C2201/04Heavy metals
    • F05C2201/0433Iron group; Ferrous alloys, e.g. steel
    • F05C2201/0448Steel
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F05INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
    • F05CINDEXING SCHEME RELATING TO MATERIALS, MATERIAL PROPERTIES OR MATERIAL CHARACTERISTICS FOR MACHINES, ENGINES OR PUMPS OTHER THAN NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES
    • F05C2253/00Other material characteristics; Treatment of material
    • F05C2253/16Fibres

Abstract

A light metal alloy piston (2) has a reinforced crown comprising a layer or mat (1) of whiskers or fibres of reinforcing material embedded in and having its interstices filled by the light metal alloy. The piston is formed in a mould or die in the crown-down position by disposing a mat of whiskers or fibres of reinforcing material in the bottom of the mould, and introducing the metal alloy by a squeeze casting technique so that the whiskers are embedded in the metal alloy. <IMAGE>

Description

SPECIFICATION Pistons The present invention relates to pistons for internal combustion engines.
It is known that a piston of a light metal alloy such as an aluminium alloy, and particularly a diesel piston having a combustion bowl, may experience cracking on the crown under certain operational cycles. Such cracking is more prevalent around the edge of the combustion bowl and may be particularly severe if the combustion bowl is of the re-entrant type.
It is also known that such cracking can be eliminated by the use of a cast-in reinforcement made from high strength, high thermal conductivity copper alloys, such as for example beryllium-copper and copper-nickel-silicon bronze, whereby the crack-susceptible edge of the combustion bowl is machined within the copper alloy material.
Because the strength ofthe aluminium alloy in the piston crown around the copper alloy reinforcement is inadequate to withstand stresses imposed by the inertia load of the copper-alloy reinforcement it is usually necessary to anchor the reinforcement by projecting legs (which may be of stainless steel or of copper alloy) into the cooler parts of the piston.
However the production of such a piston gives rise to problems. These basically are: a) accuaracy of location if the piston is made by conventional crown-up casting techniques, and b) of ensuring freedom from skirt porosity if the casting is cast crown-down, thereby facilitating accurate location of the reinforcement and anchor legs.
The present invention has for its object to provide a method of making a light metal alloy piston having a reinforced crown which overcomes or substantially eliminates the problem of piston crown cracking above referred to, which does not rely on anchoring legs or intermetallic bonding for anchoring the reinforcement to the piston alloy, and which at the same time improves the mechanical properties of the parent casting alloy by substantially eliminating casting porosity, particularly in the thinner parts of the casting. A further object of the invention is to provide a light metal alloy piston having a reinforced crown and possessing the above structural characteristics..
According to the invention, the method of making a light metal alloy piston having a reinforced crown includes the steps of: a) arranging a piston mould or die in the crowndown position, i.e. with the portion of the mould or die which forms the piston crown lowermost, b) positioning a mat of whiskers or fibres of reinforcing material on the bottom surface of the mould or die to cover the whole or a selected part or selected parts of said surface.
c) introducing into the mould or die a molten mass of a light metal alloy to cover the mat and fill the mould or die, d) applying to the molten mass in the mould or die sufficient pressure to overcome the surface tension between said mat and said molten mass to ensure that the molten mass penetrates and fills the interstices of the mat, e) allowing the molten alloy to solidify in contact with the mat of whiskers or fibres to form a composite casting having the whiskers or fibres embedded in the light metal alloy.
The composite casting is machined to produce the finished piston.
The invention also consists in a light metal alloy piston having a reinforced crown, characterised in that the reinforcement comprises a layer or mat of whiskers or fibres of reinforcing material embedded in and having its interstices filled by the light metal alloy.
The light metal alloy is preferably an aluminium alloy, such as an aluminium-silicon alloy.
Substantially pure aluminium may also be used.
The whiskers or fibres are preferably alumina (Al203) or silicon carbide (SiC). The preferred diameter of the whiskers or fibres is about 2 to about 5 micron metres. The mat may be produced by the process described in U.K. Patent No.
1 489346. Other refractory oxides or metallides may be used; also high strength and high thermal conductivity metals, such as beryllium-copper alloys and copper-nickel-silicon bronze.
The mat positioned on the bottom surface of the mould or die may have a thickness of 6 to 10 mm and a porosity such that when infiltrated with the metal alloy there will be a 540% by volume of whiskers of fibres, preferably about 20%.
The mat simply rests on the bottom surface of the mould or die and is held there by the molten alloy introduced through the top of the mould or die for example at a temperature of about 670-7400C so that means for locating the mat in the mould or die are unnecessary. The mat may extend over the whole of the bottom surface of the mould or die or may be in the form of a ring so that the central part of the crown which is machined away to form the combustion bowl consists essentially of the light metal alloy, the reinforcement existing around the edge of the combustion bowl. Such an annular mat need not extend to the outer periphery of the crown.
Pressure may be applied to the molten metal by a ram above the cavity in the mould or die. The ram is forced down in contact with the molten metal, causing the molten metal to penetrate downwards and fill the interstices of the mat, at the same time improving the mechanical properties of the alloy and reducing porosity in the casting, particularly in the piston skirt and other thin-section parts of the casting. The squeeze casting load applied may be from 2 to 20 tons psi (31 5-31 50 kg/cm2) depending on the size of the piston, and the load may be held from 55 seconds to 2 minutes, again depending on the size of the section being cast.
The whiskers or fibres of the mat may be in random array or may be oriented in a particular direction in which extra strength is required. If desired the whiskers or fibres may be pre-heated, for example to 200 to 3500C.
An embodiment of the invention is shown in the accompanying drawing in which an annular mat 1 of whiskers or fibres is embedded in the crown of the light metal alloy 1 of the piston.

Claims (10)

1. A method of making a light metal alloy piston having a reinforced crown including the steps of: a) arranging a piston mould or die in the crowndown position, i.e. with the portion of the mould or die which forms the piston crown lowermost, b) positioning a mat of whiskers or fibres of reinforcing material on the bottom surface of the mould or die to cover the whole or a selected part or selected parts of said surface, c) introducing into the mould or die a molten mass of a light metal alloy to cover the mat and fill the mould or die, d) applying to the molten mass in the mould or die sufficient pressure to overcome the surface tension between said mat and said molten mass to ensure that the molten mass penetrates and fills the interstices of the mat, e) allowing the molten alloy to solidify in contact with the mat of whiskers or fibres to form a composite casting having the whiskers or fibres embedded in the light metal alloy.
2. A method as claimed in claim 1, in which the eentral part of the piston crown is machined away to form a combustion bowl whose edge is reinforced by the whiskers or fibres.
3. A method as claimed in claim 1, in which pressure is applied to the molten metal by a ram above the cavity in the mould or die, for example in the range from 2 to 20 tons p.s.i. (315-3150 Kg/cm2).
4. A method as claimed in claim 1, 2 or 3, in which the layer or mat of whiskers or fibres has a porosity such that when infiltrated by the metal alloy there will be a to 5 to 40% by volume of whiskers or fibres.
5. A light metal alloy piston having a reinforced crown, characterised in that the reinforcement comprises a layer or mat of whiskers or fibres of reinforcing material embedded in and having its interstices filled by the light metal alloy.
6. A piston as claimed in claim 5, in which the light metal alloy is an aluminium alloy for example an aluminium-silicon alloy.
7. A piston as claimed in claim 5 or 6, in which the whiskers or fibres are selected from, alumina, silicon carbide, a beryllium-copper alloy or a copper-nickel-silicon bronze.
8. A piston as claimed in claim 5, 6 or 7, in which the whiskers or fibres have a diameter of between 2 to 5 micron metres.
9. A piston as claimed in any of claims 5 to 8, in which the layer or mat of whiskers or fibres is of annular form.
10. A piston as claimed in any of claims 5 to 9, in which the piston crown is formed with a combustion bowl whose edge is reinforced by the whiskers or fibres.
GB08128674A 1981-09-22 1981-09-22 Squeeze casting of pistons Expired GB2106433B (en)

Priority Applications (5)

Application Number Priority Date Filing Date Title
GB08128674A GB2106433B (en) 1981-09-22 1981-09-22 Squeeze casting of pistons
DE19823234504 DE3234504A1 (en) 1981-09-22 1982-09-17 PISTON FOR INTERNAL COMBUSTION ENGINES AND METHOD FOR THE PRODUCTION THEREOF
FR8215983A FR2513153B1 (en) 1981-09-22 1982-09-22 PISTON FOR INTERNAL COMBUSTION ENGINE AND MANUFACTURING METHOD THEREOF
JP57165968A JPS58100642A (en) 1981-09-22 1982-09-22 Piston and manufacture
IT46860/82A IT1159218B (en) 1981-09-22 1982-09-22 PISTON FOR ENGINES IN GENERAL

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
GB08128674A GB2106433B (en) 1981-09-22 1981-09-22 Squeeze casting of pistons

Publications (2)

Publication Number Publication Date
GB2106433A true GB2106433A (en) 1983-04-13
GB2106433B GB2106433B (en) 1985-11-06

Family

ID=10524678

Family Applications (1)

Application Number Title Priority Date Filing Date
GB08128674A Expired GB2106433B (en) 1981-09-22 1981-09-22 Squeeze casting of pistons

Country Status (5)

Country Link
JP (1) JPS58100642A (en)
DE (1) DE3234504A1 (en)
FR (1) FR2513153B1 (en)
GB (1) GB2106433B (en)
IT (1) IT1159218B (en)

Cited By (18)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO1984002096A1 (en) * 1982-11-24 1984-06-07 Ae Plc The connection of aluminium or aluminium alloys to other metal materials
GB2135222A (en) * 1983-02-04 1984-08-30 Ae Plc The reinforcement of pistons of aluminium or aluminium alloys
WO1985004605A1 (en) * 1984-04-07 1985-10-24 Gkn Technology Limited Method of squeeze forming metal articles
GB2158185A (en) * 1984-05-01 1985-11-06 Ae Plc Reinforced light metal pistons
EP0171567A2 (en) * 1984-08-16 1986-02-19 Mahle Gmbh Internal-combustion engine piston with a fibre-reinforced combustion chamber cavity
GB2163072A (en) * 1984-05-30 1986-02-19 Ae Plc The manufacture of pistons
EP0184864A1 (en) * 1984-12-05 1986-06-18 KOLBENSCHMIDT Aktiengesellschaft Cast construction parts for internal-combustion engines incorporating reinforcing elements, and method for producing the connection between the parts and the elements
GB2173134A (en) * 1985-04-04 1986-10-08 Imp Clevie Inc Cast metal composite article
WO1986005774A1 (en) * 1985-04-02 1986-10-09 Aeplc Fibre reinforced ceramics
FR2592374A1 (en) * 1985-12-27 1987-07-03 Peugeot CERAMIC-METAL DIRECT LINKING PROCESS
US4715422A (en) * 1983-01-18 1987-12-29 Ae Plc Reinforcement of articles of cast metal or metal alloy
US4804033A (en) * 1985-07-26 1989-02-14 Ae Plc Production of engineering components
US4966221A (en) * 1983-05-18 1990-10-30 Mazda Motor Corporation Method of producing aluminum alloy castings and piston made of aluminum alloy
US4995444A (en) * 1987-03-02 1991-02-26 Battelle Memorial Institute Method for producing metal or alloy casting composites reinforced with fibrous or particulate materials
US5354528A (en) * 1990-12-26 1994-10-11 Tokai Carbon Co., Ltd. Process for producing preform for metal matrix composite
WO2002049790A1 (en) * 2000-12-21 2002-06-27 Jury Alexandrovich Tsyrulnik Method for producing pistons for internal combustion engines
WO2013155131A3 (en) * 2012-04-12 2014-01-16 Rel, Inc. Thermal isolation for casting articles
CN112648104A (en) * 2020-12-07 2021-04-13 中国兵器科学研究院宁波分院 Whisker reinforced aluminum alloy piston and preparation method thereof

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GB2123727B (en) * 1982-06-25 1985-11-20 Ae Plc Pressure-casting pistons
US4546048A (en) * 1984-03-23 1985-10-08 Dana Corporation Composite thermal shield for engine components
BR8500556A (en) * 1985-02-07 1986-09-09 Metal Leve S/A. Industria E Comercio PUMP AND PUMP MANUFACTURING PROCESS FOR INTERNAL COMBUSTION ENGINES
DE3700651A1 (en) * 1987-01-12 1988-07-21 Kloeckner Humboldt Deutz Ag Cylinder head for air-cooled internal combustion engines
JPH086637B2 (en) * 1988-03-09 1996-01-29 トヨタ自動車株式会社 Piston for internal combustion engine made of fiber reinforced aluminum alloy
DE4243023A1 (en) * 1992-12-18 1994-06-23 Audi Ag Ceramic reinforced composite, used for moving internal combustion engine components.
DE19712624C2 (en) * 1997-03-26 1999-11-04 Vaw Motor Gmbh Aluminum matrix composite and process for its manufacture
US8707853B1 (en) 2013-03-15 2014-04-29 S.P.M. Flow Control, Inc. Reciprocating pump assembly
USD726224S1 (en) 2013-03-15 2015-04-07 S.P.M. Flow Control, Inc. Plunger pump thru rod
MX2017000021A (en) 2014-06-27 2017-05-01 Spm Flow Control Inc Pump drivetrain damper system and control systems and methods for same.
MX2017000888A (en) 2014-07-25 2017-05-04 Spm Flow Control Inc Bearing system for reciprocating pump and method of assembly.
CA2972031C (en) 2014-12-22 2020-01-07 S.P.M. Flow Control, Inc. Reciprocating pump with dual circuit power end lubrication system
USD759728S1 (en) 2015-07-24 2016-06-21 S.P.M. Flow Control, Inc. Power end frame segment
US10436766B1 (en) 2015-10-12 2019-10-08 S.P.M. Flow Control, Inc. Monitoring lubricant in hydraulic fracturing pump system

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DE455368C (en) * 1926-08-17 1928-01-30 Richard Mueller Process for the production of light metal pistons with cast-in chucks for the sealing rings
DE654297C (en) * 1935-05-27 1937-12-16 Eisenbau A G Gas heater
GB807633A (en) * 1956-11-26 1959-01-21 Wendell Chester Cheney Piston with head insert and process of making it
JPS5260222A (en) * 1975-09-30 1977-05-18 Honda Motor Co Ltd Method of manufacturing fibre reinforced composite
JPS5292827A (en) * 1976-01-16 1977-08-04 Honda Motor Co Ltd Method of manufacturing structures with fiber reinforced composite parts
US4137887A (en) * 1976-06-11 1979-02-06 Perkins Engines Limited Pistons for internal combustion engines
JPS5341622A (en) * 1976-09-27 1978-04-15 Honda Motor Co Ltd Piston made of fiber-reinforced light alloy
JPS5442333A (en) * 1977-08-08 1979-04-04 Honda Motor Co Ltd Production of fiberrreinforced composite material
DE2743512A1 (en) * 1977-08-27 1979-03-01 Eugen Stump IC engine piston suppressing noise - has chromium plated rim ring held with heat resistant expansion layer
GB1598585A (en) * 1978-05-03 1981-09-23 Wellworthy Ltd Pistons
GB1595280A (en) * 1978-05-26 1981-08-12 Hepworth & Grandage Ltd Composite materials and methods for their production

Cited By (25)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO1984002096A1 (en) * 1982-11-24 1984-06-07 Ae Plc The connection of aluminium or aluminium alloys to other metal materials
US4715422A (en) * 1983-01-18 1987-12-29 Ae Plc Reinforcement of articles of cast metal or metal alloy
GB2135222A (en) * 1983-02-04 1984-08-30 Ae Plc The reinforcement of pistons of aluminium or aluminium alloys
US4966221A (en) * 1983-05-18 1990-10-30 Mazda Motor Corporation Method of producing aluminum alloy castings and piston made of aluminum alloy
WO1985004605A1 (en) * 1984-04-07 1985-10-24 Gkn Technology Limited Method of squeeze forming metal articles
US4667727A (en) * 1984-04-07 1987-05-26 Gkn Technology Limited Method of squeeze forming metal articles
GB2158185A (en) * 1984-05-01 1985-11-06 Ae Plc Reinforced light metal pistons
US4651631A (en) * 1984-05-30 1987-03-24 Ae Plc Manufacture of pistons
GB2163072A (en) * 1984-05-30 1986-02-19 Ae Plc The manufacture of pistons
EP0171567A3 (en) * 1984-08-16 1987-02-04 Mahle Gmbh Internal-combustion engine piston with a fibre-reinforced combustion chamber cavity
EP0171567A2 (en) * 1984-08-16 1986-02-19 Mahle Gmbh Internal-combustion engine piston with a fibre-reinforced combustion chamber cavity
EP0184864A1 (en) * 1984-12-05 1986-06-18 KOLBENSCHMIDT Aktiengesellschaft Cast construction parts for internal-combustion engines incorporating reinforcing elements, and method for producing the connection between the parts and the elements
WO1986005774A1 (en) * 1985-04-02 1986-10-09 Aeplc Fibre reinforced ceramics
GB2173134A (en) * 1985-04-04 1986-10-08 Imp Clevie Inc Cast metal composite article
US4804033A (en) * 1985-07-26 1989-02-14 Ae Plc Production of engineering components
FR2592374A1 (en) * 1985-12-27 1987-07-03 Peugeot CERAMIC-METAL DIRECT LINKING PROCESS
EP0230192A1 (en) * 1985-12-27 1987-07-29 Automobiles Peugeot Method for a direct ceramic-metal bond
US4995444A (en) * 1987-03-02 1991-02-26 Battelle Memorial Institute Method for producing metal or alloy casting composites reinforced with fibrous or particulate materials
US5354528A (en) * 1990-12-26 1994-10-11 Tokai Carbon Co., Ltd. Process for producing preform for metal matrix composite
WO2002049790A1 (en) * 2000-12-21 2002-06-27 Jury Alexandrovich Tsyrulnik Method for producing pistons for internal combustion engines
WO2013155131A3 (en) * 2012-04-12 2014-01-16 Rel, Inc. Thermal isolation for casting articles
US9180511B2 (en) 2012-04-12 2015-11-10 Rel, Inc. Thermal isolation for casting articles
US10179364B2 (en) 2012-04-12 2019-01-15 Rel, Inc. Thermal isolation for casting articles
US10434568B2 (en) 2012-04-12 2019-10-08 Loukus Technologies, Inc. Thermal isolation spray for casting articles
CN112648104A (en) * 2020-12-07 2021-04-13 中国兵器科学研究院宁波分院 Whisker reinforced aluminum alloy piston and preparation method thereof

Also Published As

Publication number Publication date
DE3234504A1 (en) 1983-04-07
JPS58100642A (en) 1983-06-15
FR2513153B1 (en) 1987-01-09
FR2513153A1 (en) 1983-03-25
GB2106433B (en) 1985-11-06
IT1159218B (en) 1987-02-25
IT8246860A0 (en) 1982-09-22

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PCNP Patent ceased through non-payment of renewal fee

Effective date: 19990922