GB2163072A - The manufacture of pistons - Google Patents
The manufacture of pistons Download PDFInfo
- Publication number
- GB2163072A GB2163072A GB08513418A GB8513418A GB2163072A GB 2163072 A GB2163072 A GB 2163072A GB 08513418 A GB08513418 A GB 08513418A GB 8513418 A GB8513418 A GB 8513418A GB 2163072 A GB2163072 A GB 2163072A
- Authority
- GB
- United Kingdom
- Prior art keywords
- piston
- piston portion
- main
- squeeze
- combustion bowl
- 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
Links
- 238000004519 manufacturing process Methods 0.000 title claims description 12
- 238000000034 method Methods 0.000 claims description 50
- 238000002485 combustion reaction Methods 0.000 claims description 30
- 238000009716 squeeze casting Methods 0.000 claims description 24
- 230000005484 gravity Effects 0.000 claims description 18
- 230000002787 reinforcement Effects 0.000 claims description 12
- 238000003466 welding Methods 0.000 claims description 11
- 238000004512 die casting Methods 0.000 claims description 7
- 238000005242 forging Methods 0.000 claims description 6
- 239000000463 material Substances 0.000 claims description 5
- CWYNVVGOOAEACU-UHFFFAOYSA-N Fe2+ Chemical compound [Fe+2] CWYNVVGOOAEACU-UHFFFAOYSA-N 0.000 claims description 3
- 230000013011 mating Effects 0.000 claims description 2
- 230000008901 benefit Effects 0.000 description 10
- 229910052751 metal Inorganic materials 0.000 description 10
- 239000002184 metal Substances 0.000 description 10
- 229910000838 Al alloy Inorganic materials 0.000 description 4
- 239000004411 aluminium Substances 0.000 description 4
- 229910052782 aluminium Inorganic materials 0.000 description 4
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 description 4
- 230000015572 biosynthetic process Effects 0.000 description 4
- 238000005266 casting Methods 0.000 description 3
- 230000000875 corresponding effect Effects 0.000 description 3
- 229910001092 metal group alloy Inorganic materials 0.000 description 3
- 229910000826 Lo-Ex Inorganic materials 0.000 description 2
- 230000000694 effects Effects 0.000 description 2
- 239000000835 fiber Substances 0.000 description 2
- 238000010348 incorporation Methods 0.000 description 2
- 238000003754 machining Methods 0.000 description 2
- 230000004048 modification Effects 0.000 description 2
- 238000012986 modification Methods 0.000 description 2
- 150000003839 salts Chemical group 0.000 description 2
- 238000007711 solidification Methods 0.000 description 2
- 230000008023 solidification Effects 0.000 description 2
- 241001125877 Gobio gobio Species 0.000 description 1
- 229920000914 Metallic fiber Polymers 0.000 description 1
- 230000009286 beneficial effect Effects 0.000 description 1
- 238000009750 centrifugal casting Methods 0.000 description 1
- 239000000919 ceramic Substances 0.000 description 1
- 238000010276 construction Methods 0.000 description 1
- 238000001816 cooling Methods 0.000 description 1
- 230000007547 defect Effects 0.000 description 1
- 238000010894 electron beam technology Methods 0.000 description 1
- 229920000136 polysorbate Polymers 0.000 description 1
- 238000007493 shaping process Methods 0.000 description 1
Classifications
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F02—COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
- F02F—CYLINDERS, PISTONS OR CASINGS, FOR COMBUSTION ENGINES; ARRANGEMENTS OF SEALINGS IN COMBUSTION ENGINES
- F02F3/00—Pistons
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F02—COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
- F02F—CYLINDERS, PISTONS OR CASINGS, FOR COMBUSTION ENGINES; ARRANGEMENTS OF SEALINGS IN COMBUSTION ENGINES
- F02F3/00—Pistons
- F02F3/16—Pistons having cooling means
- F02F3/20—Pistons having cooling means the means being a fluid flowing through or along piston
- F02F3/22—Pistons having cooling means the means being a fluid flowing through or along piston the fluid being liquid
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23P—METAL-WORKING NOT OTHERWISE PROVIDED FOR; COMBINED OPERATIONS; UNIVERSAL MACHINE TOOLS
- B23P15/00—Making specific metal objects by operations not covered by a single other subclass or a group in this subclass
- B23P15/10—Making specific metal objects by operations not covered by a single other subclass or a group in this subclass pistons
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F02—COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
- F02F—CYLINDERS, PISTONS OR CASINGS, FOR COMBUSTION ENGINES; ARRANGEMENTS OF SEALINGS IN COMBUSTION ENGINES
- F02F3/00—Pistons
- F02F3/0015—Multi-part pistons
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
- F16J—PISTONS; CYLINDERS; SEALINGS
- F16J1/00—Pistons; Trunk pistons; Plungers
- F16J1/005—Pistons; Trunk pistons; Plungers obtained by assembling several pieces
-
- 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
- F02F2200/00—Manufacturing
- F02F2200/04—Forging of engine parts
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
- F05C—INDEXING SCHEME RELATING TO MATERIALS, MATERIAL PROPERTIES OR MATERIAL CHARACTERISTICS FOR MACHINES, ENGINES OR PUMPS OTHER THAN NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES
- F05C2201/00—Metals
- F05C2201/02—Light metals
- F05C2201/021—Aluminium
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10S—TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10S29/00—Metal working
- Y10S29/048—Welding with other step
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T29/00—Metal working
- Y10T29/49—Method of mechanical manufacture
- Y10T29/49229—Prime mover or fluid pump making
- Y10T29/49249—Piston making
- Y10T29/49252—Multi-element piston making
- Y10T29/49254—Utilizing a high energy beam, e.g., laser, electron beam
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T29/00—Metal working
- Y10T29/49—Method of mechanical manufacture
- Y10T29/49229—Prime mover or fluid pump making
- Y10T29/49249—Piston making
- Y10T29/49256—Piston making with assembly or composite article making
- Y10T29/49259—Piston making with assembly or composite article making with fiber reinforced structure
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T29/00—Metal working
- Y10T29/49—Method of mechanical manufacture
- Y10T29/4998—Combined manufacture including applying or shaping of fluent material
- Y10T29/49988—Metal casting
Description
1 GB 2 163 072 A 1
SPECIFICATION
The manufacture of pistons The invention relates to the manufacture of pis- 70 tons.
It has been customary to manufacture the basic piston shape by a single piston-forming process; by forging, by gravity die casting or, more recently, by squeeze casting methods in which molten metal is gravity. fed to an open die, the die then being closed and the metal solidified under a force of many tonnes. Each of these methods has advan tages in the formation of certain parts of the piston but disadvantages in the formation of certain other 80 parts of the piston.
in the case of forging, this method has the bene fit of producing high strength so that highly stressed parts of the piston, such as gudgeon pin bosses, are very strong when forged. It has the disadvantage, however, that it is difficult to pro duce crown end piston features, such as combus tion bowls or piston ring grooves, by forging; these require subsequent machining and, possibly, shaping operations.
Gravity die casting has the advantage that pis tons can be produced easily and cheaply by this method. The incorporation of inserts can be readily accomplished by using, for example, the Al-Fin bond. Gravity die casting has the disadvantage, however, that it does not have high strength, as compared with forging, and is not particularly re sistant to the elevated temperatures often found at the crown end of a.piston, particularly where that piston is for a diesel engine.
Squeeze casting has the advantage that a piston so produced has a more uniform structure than gravity cast pistons, with an absence of voids. This makes the piston mechanically stronger as well as improving generally the properties of material. The production of pistons by squeeze casting is, how ever, more expensive and time-consuming than their production by conventional gravity die cast ing. In addition, while the improved properties are desirable or necessary in certain parts of the pis tons such as the crown region, they are not as de sirle or necessary in other portions of the pistons, such as the lower skirt region. This is par ticuiarly true where the pistons are very large die sel pistons where the crown is subject to high temperatures and where the volume of material in volved in the manufacture of the piston makes squeeze casting expensive.
According to a first aspect of the invention, there is provided a method of manufacturing a piston for an internal combustion engine, comprising forming the piston from main and second piston portions co nected together by a welding technique, the main piston portion being formed by a first piston forming process and the second piston portion being formed by q second piston forming process, with said second piston portion including at least a part thereof which is more resistant than said main piston portion, and then forming in said resistant part, a piston ring groove having spaced radially extending surfaces interconnected by a base.
According to a second aspect of the invention, there is provided a piston when made by the method of the first aspect of the invention.
The following is a more detailed description of some embodiments of the invention, by way of example, reference being made to the accompanying drawings in which:-
Figure 1 is a cross-section of part of a crown end of a first piston for an internal combustion engine, which is formed from main and second portions connected together by a welding technique, Figure 2 is a similar view to Figure 1, showing a second piston for an internal combustion engine, which is formed from main, second and third portions connected together by a welding technique, Figure 3 is a schematic part-section of a squeeze casting die showing the formation of the third portion of the piston of Figure 2, 85 Figure 4 is a similar view to Figure 1, showing a third piston for an internal combustion engine, which is formed from main and second portions connected together by a welding technique, the second portion forming an entrance for a combus- tion bowl of the piston, Figure 5 is a similar view to Figure 4 showing a first modification of the third piston in which the part of the second piston portion forming the com bustion bowl entrance, is reinforced, Figure 6 is a similar view to Figures 4 and 5, showing a second modification of the third piston in which the second piston portion is connected to the main piston portion by a weld which intersects in a straight line planes including the piston axis, and Figure 7 is a similar view to Figure 1 and showing a fourth piston for an internal combustion engine, which is formed from main, second and third piston portions, the second and third piston por- tions being connected separately to the main piston portion.
Referring first to Figure 1, the first piston, which may, for example, be a large piston for a diesel engine, is formed by a main piston portion 10 and a second piston portion 11, connected to the main portion by a weld 12. The main piston portion is either gravity die cast or forged from aluminium or an aluminium alloy. The first piston portion 10 forms a complete combustion bowl 18 including an entrance 22. This portion 10 is also machined to provide a lowermost piston ring groove 14d and an inner and lower portion 26 of a gallery 13 extending around the crown of the piston for cooling oil. Also provided are two L-shaped rebates 27, 28, one, 27 leading upwardly from the upper edge of the gallery portion 26 to the crown surface and the other, 28, leading from the lower edge of the gallery portion to a ring band 15.
A second piston portion 11 is formed by a squeeze casting process from a molten aluminium or aluminium alloy such as Lo-Ex.The molten metal or metal alloy is gravity fed into a die which is closed by a movable diemember.The molten metal is then solidified under a force of many tonnes to form the second piston portion 11. After 1 2 GB 2 163 072 A 2 solidification, the die is opened and the squeeze cast member of homogeneous metal or metal alloy is removed.
Next, the squeeze cast member is machined to form the second piston portion. In this machining, the portion 11 is shaped to be generally annular with a flat upper surface and a curved outer sur face formed with three upper piston ring grooves 14a, 14b, 14c. Each piston ring groove has spaced radially extending surfaces 46 interconnected by a base 47. The inner surface is shaped to provide the remainder 29 of the gallery 13 and is formed with two projecting L-shaped portions 30, 31 corre sponding to the two L-shaped rebates 27, 28 on the main portion 10.
After the two portions 10, 11 have been formed, they are connected together by any suitable weld ing technique, for example, an electron beam welding technique, with the-welds 12 extending only between the vertical surface of the rebate 27 85 and the corresponding vertical surface of the L shaped portion 30 of the squeeze casting 11, and between the horizontal surface of the rebate 28 and the corresponding horizontal surface of the other L-shaped portion 31. The remaining horizon- 90 tal and vertical surfaces are left unconnected, partly because their connection is not strictly nec essary and partly because of the difficulty of effect ing a connection in these regions. In this way, the complete piston is formed.
The piston has the two uppermost piston ring grooves 14a, 14b, formed wholly in squeeze cast material, which is better able to resist the wear of piston rings at operating temperatures than the metal or metal alloy of the main piston portion 10. 100 In addition, the squeeze cast second piston portion 11 provides a reinforced edge to the crown of the piston, so increasing the resistance of this part of the piston to the effects of operating temperatures.
However, the proportion of the piston formed by 105 the expensive, and comparatively more difficult, squeeze casting process is kept to a minimum; the majority of the piston being made from gravity die cast or forged aluminium or aluminium alloy.
Thus, only the parts which require the benefits of 110 squeeze casting are formed in this way and so the piston can be produced more easily and cheaply than a wholly squeeze cast piston and with better heat resistance and strength characteristics than a wholly gravity cast or forged piston.This is of par- 115 ticular benefit in large diesel pistons where the vol ume of piston material is comparatively high.
Referring next to Figure 2, parts and features common to Figure 1 and to Figure 2 are given the same reference numerals and are not described in 120 detail. In this second piston, the main piston por tion 10 is forged or gravity die cast and is formed with the part gallery 26 and the lowermost piston ring groove 14d, as in the Figure 1 embodiment, and also with the two rebates 27, 28 leading from 125 the upper and lower edges of the gallery part 26.
However, in this second piston, the upper end of the upper rebate 27 does not lead to a crown of the piston, but it instead extends radially inwardly to a side wall 16 of the combustion bowl 18. 130 Second and third squeeze cast piston portions are then formed. The second piston portion 11 is formed by squeeze casting in generally the same way as the second piston portion 11 of the embod- iment of Figure 1. However, in this second portion 11, a reinforcement 36 of fibres or whiskers is provided in the region of the uppermost piston ring groove 14a so that, when formed, this groove 14a has radially extended surfaces 46 and a base 47 reinforced against wear by the associated piston ring groove The third piston portion 35 is formed in the following way (see Figure 3). First, a wad or mat 40 of fibres or whiskers are placed in a lower die part 41 of a squeeze casting apparatus. These fibres may be ceramic or metallic fibres or whiskers. The die, when closed by an upper die part 42, is of generally cylindrical corffiguration. The size of mat or wad 40 is such that it does not fill the closed die completely but leaves a space therearound and thereabove. A molten aluminium or aluminium alloy, such a Lo-Ex, is then gravity fed into the die which is closed by the upper die- part 42. The molten metal is solidified under a force of many tonnes which forces the molten metal into the mat or wad of fibres to form an intimate bond therebe- tween.
After solidification the die is opened and the squeeze cast member 43 so formed is removed.
This member is generally cylindrical in shape Isee Figure 3) and has a central portion reinforced by the fibres or whiskers. The squeeze casting process ensures that the member is free from voids and other strength reducing defects and also ensures a strong intimate bond between the fibres or whiskers and the metal. The fibres or whiskers improve the heat resistance of the member and also improve its strength.
The member is next machined to produce the third piston portion 35 in the form of an annular insert whose inner portion defines an entrance 22 to the combustion bowl 18 and which has a lower surface 23 and an axially extending outer surface 24 meeting at a circular edge. The lower surface 23 is inclined upwardly towards the centre of the insert.
To complete the piston, the third piston portion 35 is connected to -the main portion 10 by a weld 12 between the lower surface 23 of the portion 35 and the upper radially inwardly extending surface of the rebate 27. The second reinforced portion 11 is connected to this assembly in a manner described above with reference to Figure 1.
In this way, the completed piston has a reinforced entrance 22 to the combustion bowl 18 which is more heat resistant than the remainder of the piston, and a reinforced upper piston ring groove 14a Which is more wear resistant than the remaining grooves.This latter eliminates the need for the use of precast piston ring reinforcement inserts and their incorporation by the so-called Al-Fin process. In addition, in both the first-and the second pistons, the gallery 13 is formed without use of a salt core casting process. This simplifies considerably the casting steps.
1 3 GB 2 163 072 A 3 However, as shown in broken line in Figure 2, the second piston portion 11 may incorporate the whole of the gallery 13, which may be formed in the portion 11 by a salt core process. This has the benefit that the second piston portion 11 is of less complex shape. In addition, it allows unbroken welds 12 between this portion 11 and the main piston portion 10.
Referring next to Figure 4, parts common to Fig- ure 4 and to Figures 1 to 3 will be given the same reference numerals and will not be described in detail. The third piston is formed by a main piston portion 10 and a second piston portion 11. The main piston portion is gravity die cast or forged, in the same way as the main piston portion 10 of the piston of Figure 1.
The second piston portion 11 is formed by squeeze casting in generally the same way as the piston portion 11 of the pistons of Figures 1 and 2.
However, the second piston portion 11 of the piston of Figure 3 forms the top three piston ring grooves 14a, 14b and 14c and the upper surface and part of the base of the lowermost piston ring groove 14d. Further, this second piston portion 11 includes a ferrous insert 37 incorporated during squeeze casting and connected to the squeeze cast metal by an Al-Fin bond. The insert 37 is so located that in it is formed the uppermost piston ring groove 14a.
Further, this second piston portion 11 defines the whole of the crown of the piston and includes the entrance 22 to the combustion bowl 18.
The second piston portion 11 is shaped to fit in the rebate 28 leading from the lower edge of the gallery portion 26 to the ring band 15 and on a frusto-conical surface 38 leading from the upper edge of the gallery portion 26 to the interior wall of the combustion bowl 18. The second portion 11 is connected to the main piston portion by welds ex tending between these surfaces, as described 105 above.
In this way, the benefits of the squeeze cast crown and the reinforced piston ring groove are obtained without the need for squeeze casting the whole piston. The squeeze cast second piston por tion provides a resistant crown combustion bowl entrance and second and third piston ring grooves 14b ' 14c and the ferrous insert 37 provides a rein forced upper piston ring groove 14a with radially extending surfaces 46 and a base 47.
Referring next to Figure 5, the fourth piston is generally similar to the third piston and parts com mon to Figures 4 and 5 will be given the same ref erence numerals and will not be described in detail. The-difference between the piston of Figure 120 4 and the piston of Figure 5 is that, in the piston of Figure 5, the second piston portion is provided with two reinforcements of fibres or whiskers of any of the kinds described above with reference to Figures 1 to 3. These reinforcements are incorpo rated into the second piston portion during its squeeze casting, as also described above with ref erences to Figure 1 to 3.
One reinforcement 38 reinforces the outer edge of the crown and the uppermost piston ring groove 130 14a while the other fibre reinforcement 39 reinforces the entrance 22 to the combustion bowl 18. As seen in broken line in Figure 6, the casting from which the second piston portion 11 is made has the part which is to form the entrance 22 to the combustion bowl 18 oversized; this part then being machined to shape as described above with reference to Figure 3.
In addition, the L-shaped rebate 28 is omitted with the main piston portion 10 and the second piston portion 11 meeting, in this region, at respective annular surfaces extending between the gallery 13 and the ring band 15 and the gallery 13 and the combustion bowl 18. As a result of this, the second piston portion 11 forms only the upper and second piston ring grooves 14a, 14b. The third and fourth piston ring grooves 14c, 14d are formed in the main piston portion 10.
Referring next to Figure 6, this figure shows a modified form of the piston of Figure 5 and parts common to Figures 5 and 6 are given the same reference numerals and will not be described in detail. In this embodiment, the connection between the main piston portion 10 and the second piston portion 11 is on respective mating frusto-conical surfaces 50, 51 inclining downwardly from the combustion bowl 18 to intersect the gallery 13 and terminate at the ring band. As a resultof this, the two parts can be connected together by a single weld which thus intersects in a straight line, planes including the piston axis.
This embodiment has the advantage that it is easy to manufacture, because there is only a single weld. There are no unbonded regions between the main piston portion 10 and the second piston portion 11 and the formation of the gallery 13 in two parts 26, 29 is also beneficial in the manufacture of the piston.
Referring next to Figure 7, this embodiment is similar to the embodiment of Figures 2 and 3 and parts common to Figures 2 and 3 and to Figire 7 will be given the same reference numerals and will not be described in detail. In this embodiment, the second and third piston portions 11, 35 are formed generally as described above with reference to Figures 2 and 3. However, in this embodiment, the fibre or whisker reinforcement 36 in the second piston portion 11 extends to the crown.
The main difference in this Figure 7 embodiment is that the second and third piston portions 11, 35 are not connected to one another. Rather, the main body portion 11 is formed with two generally Lshaped rebates 44, 45. The first of these rebates 44 extends from the surface of the crown and passes through the gallery 13 before emerging at the ring band 15. The second of these rebates 46 extends from the surface of the crown to the side of the combustion bowl.
The first rebate 44 receives the second piston portion 11 and is welded thereto along the lines of contact. The second L- shaped rebate 45 receives the third piston portion 35 which is welded to these surfaces.
This construction has the benefit that the piston parts can be readily assembled.
4 GB 2 163 072 A 4 Although, in the above-described embodiments, the first body portion 10 is formed by gravity die casting or forging and the second body portion 11 and the third body portion 35 (where provided) are formed by squeeze casting, it will be appreciated that any two different suitable piston-forming processes could be used. For example, where the first body portion 10 is forged, the second and/or third portions 11, 35 may be gravity die cast, with suita- ble reinforcement. Other combinations are gravity die cast or forged and centrifugal casting.
Claims (20)
1. A method of manufacturing a piston for an internal combustion engine, comprising forming the piston from main and second piston portions connected together by a welding technique, the main piston portion being formed by a first piston forming process and the second piston portion being formed by a second piston forming process, with said second piston portion including at least a part thereof which is more resistant than said main piston portion, and then forming in said resistant part, a piston ring groove having spaced radially extending surfaces interconnected by a base.
2. A _method according to claim 1, wherein the second piston portion includes a reinforcement forming said resistant part.
3. A method according to claim 2, wherein the 95 second piston portion is formed by a squeeze cast ing process, the reinforcement being provided by fibres or whiskers incorporated during said squeeze casting process.
4. A method according to claim 2, wherein the 100 second piston portion is formed by a squeeze cast ing process, the reinforcement being provided by an annular insert of a ferrous material incorporated during said squeeze casting process.
5. A method according to any one of claims 1 to 4, wherein the piston includes a combustion bowl having an entrance extending therearound, the second piston portion forming said combustion bowl entrance.
6. A method according to claim 5, wherein the second piston portion includes a reinforcement which reinforces said combustion bowl entrance.
7. A method according to claim 6, wherein the second piston portion is formed by a squeeze cast- ing process, the combustion bowl entrance reinfbrcement being provided by fibres or whiskers incorporated during said squeeze casting process.
8. A method according to any one of claims 5 to 7, wherein the main and second piston portions have mating frusto-conical surfaces extending from the combustion bowl to the ring band, the maIn and second portions being interconnected in a single welding step with the weld extending between said surfaces.
9. A method according to any one of claims 1 to 4, wherein the piston includes a combustion bowl having an entrance extending therearound, there being provided a third piston portion which is formed separately from the main and second piston portions, which forms said combustion bowl entrance and which is incorporated into the piston by a welding technique.
10. A method according to claim 9, wherein the third piston portion is formed by a squeeze casting process.
11, A method according to claim 10, wherein the squeeze cast third piston portion is reinforced with fibres or whiskers so that said combustion bowl entrance is reinforced thereby.
12. A method according to any one of claims 1 to 11, wherein the second piston portion defines at least a part of a gallery which extends around the interior of the piston.
13. A method according to claim 12, wherein the main piston portion provides an annular first part of the gallery and the second piston portion provides an annular second part of the gallery, the complete gallery being formed when the main and second piston portions are welded together. 85
14. A method according to any one of claims 1 to 13, wherein the main piston portion is formed by gravity die casting.
15. A method according to any one of claims 1 to 13, wherein the main piston portion is formed by forging,
16. A method according to claim 15 when dependant on claims 1 or 2 only, wherein the second piston portion is formed by gravity die casting.
17. A method according to any one of claims 1 to 16, wherein the welding technique is an electron. beam welding technique.
18. A method of manufacturing a piston for an internal combustion engine substantially as hereinbefore described with reference to Figure 1 or to Figures 2 and 3 or Figure 4 or Figure 5 or Figure 6 or Figure 7 of the accompanying drawings.
19. A piston when made by the method of any one of claims 1 to 18.
20. A piston substantially as hereinbefore de- scribed with reference to Figure 1 or to Figures 2 and 3 or Figure 4 or Figure 5 or Figure 6 or Figure 7 of the accompanying drawings.
Printed in the UK for HMSO, D8818935, 12/85, 7102. Published by The Patent Office, 25 Southampton Buildings, London, WC2A lAY, from which copies may be obtained.
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| GB848413800A GB8413800D0 (en) | 1984-05-30 | 1984-05-30 | Manufacture of pistons |
Publications (3)
| Publication Number | Publication Date |
|---|---|
| GB8513418D0 GB8513418D0 (en) | 1985-07-03 |
| GB2163072A true GB2163072A (en) | 1986-02-19 |
| GB2163072B GB2163072B (en) | 1987-10-14 |
Family
ID=10561706
Family Applications (2)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| GB848413800A Pending GB8413800D0 (en) | 1984-05-30 | 1984-05-30 | Manufacture of pistons |
| GB08513418A Expired GB2163072B (en) | 1984-05-30 | 1985-05-28 | The manufacture of pistons |
Family Applications Before (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| GB848413800A Pending GB8413800D0 (en) | 1984-05-30 | 1984-05-30 | Manufacture of pistons |
Country Status (7)
| Country | Link |
|---|---|
| US (1) | US4651631A (en) |
| EP (1) | EP0178747B2 (en) |
| JP (1) | JPS6158955A (en) |
| KR (1) | KR950014411B1 (en) |
| CA (1) | CA1240132A (en) |
| DE (2) | DE3562323D1 (en) |
| GB (2) | GB8413800D0 (en) |
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| CN101903632B (en) * | 2007-12-20 | 2012-09-05 | 马勒国际公司 | Method for fixing an annular element on a piston for an internal combustion engine |
| DE102011013143A1 (en) * | 2011-03-04 | 2012-09-06 | Mahle International Gmbh | Piston for an internal combustion engine and method for its production |
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| GB1069609A (en) * | 1964-11-25 | 1967-05-17 | Hermann Mahle | Piston for internal combustion engines |
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| GB2134021A (en) * | 1983-01-18 | 1984-08-08 | Ae Plc | Element for encasting in article of cast metal or metal alloy |
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1985
- 1985-05-28 DE DE8585303736T patent/DE3562323D1/en not_active Expired
- 1985-05-28 GB GB08513418A patent/GB2163072B/en not_active Expired
- 1985-05-28 EP EP85303736A patent/EP0178747B2/en not_active Expired - Lifetime
- 1985-05-28 DE DE198585303736T patent/DE178747T1/en active Pending
- 1985-05-28 CA CA000482639A patent/CA1240132A/en not_active Expired
- 1985-05-30 JP JP60115553A patent/JPS6158955A/en active Pending
- 1985-05-30 US US06/739,210 patent/US4651631A/en not_active Expired - Lifetime
- 1985-05-30 KR KR1019850003770A patent/KR950014411B1/en not_active IP Right Cessation
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| GB1069609A (en) * | 1964-11-25 | 1967-05-17 | Hermann Mahle | Piston for internal combustion engines |
| GB1075508A (en) * | 1964-11-26 | 1967-07-12 | Hermann Mahle | Internal combustion engine piston |
| GB1097056A (en) * | 1965-03-13 | 1967-12-29 | Mahle Kg | Internal combustion engine piston |
| GB2106433A (en) * | 1981-09-22 | 1983-04-13 | Ae Plc | Squeeze casting of pistons |
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Cited By (8)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| GB2271521A (en) * | 1992-10-06 | 1994-04-20 | Metalock | Reconditioning engine parts |
| GB2271521B (en) * | 1992-10-06 | 1996-01-31 | Metalock | Reconditioning engine parts |
| WO2009033446A1 (en) * | 2007-09-15 | 2009-03-19 | Mahle International Gmbh | Two-piece piston for an internal combustion engine |
| US8225765B2 (en) | 2007-09-15 | 2012-07-24 | Mahle International Gmbh | Two-part piston for an internal combustion engine |
| CN101903632B (en) * | 2007-12-20 | 2012-09-05 | 马勒国际公司 | Method for fixing an annular element on a piston for an internal combustion engine |
| DE102011013143A1 (en) * | 2011-03-04 | 2012-09-06 | Mahle International Gmbh | Piston for an internal combustion engine and method for its production |
| WO2020123094A1 (en) * | 2018-12-13 | 2020-06-18 | Caterpillar Inc. | Method for remanufacturing a used piston and piston |
| US10926362B2 (en) | 2018-12-13 | 2021-02-23 | Caterpillar Inc. | Remanufactured engine piston and method |
Also Published As
| Publication number | Publication date |
|---|---|
| US4651631A (en) | 1987-03-24 |
| EP0178747A1 (en) | 1986-04-23 |
| KR850008702A (en) | 1985-12-21 |
| JPS6158955A (en) | 1986-03-26 |
| EP0178747B1 (en) | 1988-04-27 |
| EP0178747B2 (en) | 1992-07-15 |
| DE178747T1 (en) | 1986-09-25 |
| KR950014411B1 (en) | 1995-11-27 |
| GB2163072B (en) | 1987-10-14 |
| GB8513418D0 (en) | 1985-07-03 |
| DE3562323D1 (en) | 1988-06-01 |
| GB8413800D0 (en) | 1984-07-04 |
| CA1240132A (en) | 1988-08-09 |
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Legal Events
| Date | Code | Title | Description |
|---|---|---|---|
| PCNP | Patent ceased through non-payment of renewal fee |
Effective date: 20010528 |