JP2006502334A - Method for manufacturing a nozzle for a fuel valve of a diesel engine and nozzle - Google Patents

Abstract

In a mould (13) a corrosion-resistant first alloy (10) is arranged at least in an outer area which is to constitute the outer surface of a nozzle around the nozzle bores (4). A second alloy (11) is used in another area of the nozzle. The materials in the mould are treated by isostatic pressing into a consolidated material. The boundary area between the two alloys (10, 11) is free of cracks.

Description

  The present invention is a nozzle for a fuel valve of a diesel engine, in particular a two-stroke crosshead engine, wherein the first material of a corrosion-resistant first alloy constitutes the outer surface of the nozzle around the nozzle bore. To a method of manufacturing the nozzle, which is arranged in a mold in the outer region.

  The above method is well known from WO 95/24286, and the application is very good with regard to nozzle strength and corrosion resistance, after the mold is subjected to HIP treatment after filling with the first material constituting the entire nozzle. The creation of a nozzle with properties is described. Furthermore, a very accurate shape is obtained around the nozzle bore resulting in a good atomization of the fuel. In this HIP process (hot isotropic pressing), the finely granulated powder was solidified in the entire nozzle blank at high pressure and high temperature, and the nozzle blank formed was isotropically very finely granulated. Retain alloy structure.

EP 0 984 493 A1 describes a fuel valve with a nozzle that extends forward beyond the main valve seat and into the valve housing beyond the slider guide. These parts of the fuel valve are made of steel to give the valve seat etc. with the required hardness. On the bottom part of the nozzle, a corrosion protection coating is formed using laser welding, plasma welding or hot powder spraying which fully or partially bonds the molten material to the steel. The material in the bonded area has the property that the corrosion resistant alloy can be peeled off with hardening or after a period of work. During operation, the nozzles are exposed to strong high temperature cycling loads, which can lead to degradation of the adhesion of the corrosion resistant alloy.
WO95 / 24286 EP0982493A1

  The object of the present invention is to produce a long-life nozzle.

  In view of the above fact, the nozzle manufacturing method according to the present invention referred to first is that the second material of the second alloy is arranged in the inner region in the mold, and the material thus arranged is It is processed by the isotropic pressing process into a solidified (integrated) nozzle blank portion in which a microcrack is not present in a boundary region between the first alloy and the second alloy. .

  Despite the fact that the use of a second alloy in the nozzle causes a change in the structure of the nozzle and that the change in material or structure usually has a negative impact on the life, the life of the nozzle is Improved. Perhaps an improved lifetime is obtained because there are no microcracks in the boundary region between the two alloys. Solidification of different materials by using an isotropic pressing process (integral molding) produces a diffusion-adjusted solidification from the application of dissolved material on a solid material, without a boundary region of known types of properties. Even if a nozzle of the type known from EP 0 984 493 A1 is heat-treated to a more uniform hardness before its use, the microcracks are thin, very hard dissolution-based mixing areas immediately after application and affect the heat. Occurs in the area of steel affected. The diffusion-controlled solidification according to the present invention does not form any dissolution-based mixing zone with an associated zone that is affected by heat. By avoiding microcracks in the transition region between two different materials, a substantial source of fatigue failure initiation in the nozzle is eliminated, resulting in a significant improvement in nozzle life. Diffusion-controlled solidification makes the risk of bonding errors between two different materials very low.

  Preferably, the second material of the second alloy has a higher fatigue strength than the corrosion-resistant first alloy in the finished nozzle in order to obtain a further improvement in life. Fatigue strength is important for the life of the nozzle. In addition to the traditional heat-based load on the nozzle, it has so far gained more precise control of fuel injection in diesel engines and thereby better combustion of the fuel and reduced formation of pollutants. This is because a significant increase in fatigue loading is expected as a result of the use of higher injection pressures and faster pressure oscillations than those applied to.

  When at least the corrosion resistant alloy contains more than 0.6% Al, the oxygen limited diffusion barrier is used between the first material and the second material prior to the isotropic pressing process. Is preferred. The oxygen limited diffusion barrier counteracts the diffusion of oxygen released from the first alloy of the alloy into the second alloy of the alloy and reaction with alloy components or undesirable Al impurities. Oxygen can be, for example, in a decomposed state in the second alloy or can be liberated by oxide decomposition in the second alloy during heating of the material. A very small amount of oxygen, which is only a few ppm, leads to precipitation of aluminum oxide and / or other undesirable precipitation in the boundary region between the two alloys, resulting in a deterioration of the fatigue strength of the entire nozzle.

  The diffusion barrier limits or prevents the harmful diffusion of oxygen so that the nozzle maintains high fatigue strength. Obviously, a diffusion barrier can be used when the alloy contains less than 0.6% Al or exactly 0.6% Al. The positive effect of the barrier can be obtained with an alloy having an Al content in the range of 0.1 to 0.5%, for example. The alloy actually used presents a risk of metallurgical metallurgy processes that produce other undesirable precipitates, such as precipitates such as intermetallic compounds, carbides or oxides different from aluminum oxides. The diffusion barrier has a limiting effect on the transport of alloy components different from oxygen from one material to another. For example, an element having a small atomic number such as C or boron can diffuse from an alloy having a high content of the element in its free form into an alloy having a low content of the element. Limiting the carbon content in the second material cures cracks in the area of the nozzle with a complex shape, for example around the nozzle bore, for example in connection with the hardening of the nozzle to high hardness. Provides the advantage of lowering the trend.

  Such diffusion barriers are associated with corrosion resistant alloys suitable for use as nozzle materials, for example, nickel and copper, both nickel and copper are suitable for forming highly concentrated and stable coatings. Or it can have a nickel alloy. As an alternative, a cobalt coating, a cobalt alloy, or a chromium coating can be used.

  The manufacture of the nozzles can be suitably simplified by placing a diffusion barrier on the inner surface of the prefabricated first material member or on the outer surface of the prefabricated second material member. it can. The prefabricated member can function as a diffusion barrier until all material is placed in the mold and an isotropic pressing process is performed to solidify the material. At the same time, the use of a prefabricated member is a holder for particulate material where the member is stacked together with another prefabricated member or filled around or in the mold member When used as a mold, the mold can be filled quickly and easily before the pressing process.

  In the latter case, the prefabricated member is preferably made from a first material and filled with a particulate starting material of a second alloy. From a manufacturing point of view, this offers the advantageous possibility of rapid filling of the mold. At the same time, the second material is manufactured by powder metallurgy technology, thereby obtaining an isotropic structure and producing particularly good fatigue properties.

  When a prefabricated member of the first alloy is used, it is part of a mold that is cast or manufactured into a bowl-shaped or tubular wall by powder metallurgy technology and used in an isotropic pressing process Form. The use of such prefabricated components as a mold simplifies the subsequent removal of the mold from the manufactured blank when the prefabricated component is part of the finished blank. Let it be omitted.

  In a method according to another embodiment of the present invention, a preformed second material core member is placed in a mold, in which the first alloy powder is isotropically pressed. Are arranged before they are executed. Since at least a portion of the second material is preformed, the core member can be used to control the placement of the first alloy powder. The powder can be placed directly adjacent to the core member without fear of mixing the powder from the first and second alloys. The preformed core member facilitates the precise arrangement of the particulate material in the desired arrangement.

  The preformed first material member and / or the preformed second material member use, for example, a CIP process or an HIP process, where a work process or extrusion can be subsequently performed. Or using a sintering step where the next step is a pressing step, so that the member has an advantageous isotropic structure. It is also possible to use cast parts or processed materials whose properties are improved by an isotropic pressing process.

  The isotropic pressing process is suitably a HIP process that causes solidification of the material by diffusion without actually growing the particles. This makes it possible to maintain a fine particle structure due to the fact that one or more materials have a fine granular starting material that has been solidified into agglomerated material without dissolution. The isotropic pressing process may be a CIP process, in which pressurization occurs at a much lower temperature than the HIP process.

  In another aspect, the invention further relates to a fuel valve in a diesel engine, particularly a two-stroke crosshead engine having a central longitudinal channel in communication with a number of nozzle bores opening on the outer surface of the nozzle. It relates to the nozzle for. The nozzle is made of a corrosion-resistant first alloy at least in the outer region around the nozzle bore and in a region different from the outer region.

  In view of improving the life of the nozzle, as described above in connection with the description of the method according to the first aspect of the present invention, the nozzle is a boundary between the first alloy and the second alloy. The material in the region is characterized by having a structure free of microcracks.

Regarding the effects and advantages obtained with the nozzle according to the invention, reference should be made to the above description in connection with the description of the method according to the first aspect of the invention.
In a preferred embodiment, the second alloy has a higher fatigue strength than the corrosion-resistant first alloy, further contributing to achieving a longer life as described above.

  In one embodiment, an oxygen limited diffusion barrier is provided in the nozzle between the first alloy and the second alloy. The diffusion barrier is resistant to corrosion based on the desired properties and manufacturing conditions for the alloy, without having to consider whether the components of the alloy interact negatively with the components of the second alloy. This makes it possible to determine the analysis results of the first alloy. Similarly, the analysis result of the second alloy can be determined without having to consider the components of the first alloy.

The second alloy can be made by powder metallurgy techniques. This technique results in improved properties compared to the production of materials by simply dissolving into the desired component.
In a preferred embodiment, the first alloy is a nickel-based alloy and the second alloy is an iron-based alloy. The iron-based alloy used inside the nozzle provides high strength in the area of the nozzle having a complex shape. This is because a large number of nozzle bores are arranged in a small area and cut into the central longitudinal channel at different angles.

  Nickel-based alloys are susceptible to carbide formation and therefore have only a limited C content, for example up to 0.6% by weight. Conventional iron-based alloys with high fatigue strength typically have a high C content, up to a few percent by weight. If necessary, the iron-based alloy has less free carbon than the nickel-based alloy at the nozzle operating temperature. The carbide-forming alloy component in the iron-based alloy can be selected, for example, such that the carbide decomposition temperature is higher than the nozzle operating temperature and further higher than the HIP temperature when the nozzle is manufactured by the HIP process. . In this way free carbon release due to carbide decomposition is avoided. Furthermore, a strong carbide former can be selected as an alloy component that captures and bonds free carbon.

  The nozzle is suitably designed as a separate unit located in the fuel valve with an extension of the spindle guide containing the main valve seat of the fuel valve. According to this design, the nozzle is not affected by the significant stress generated in the main valve seat, or is affected only to a minimum extent. In the nozzle alternative, this alternative is limited to a smaller portion that is primarily composed of fuel valve components that protrude into the combustion chamber.

  In a further embodiment, the second alloy accounts for more than 70% of the total mass of the nozzle. This can be a cost advantage in addition to the strength advantage if the second alloy is less expensive than the first alloy.

Hereinafter, the present invention will be described in more detail with reference to the schematic drawings.
FIG. 1 shows a fuel valve nozzle in an internal combustion engine as a whole by reference numeral 1. This internal combustion engine may be a 4-stroke engine, but is preferably a 2-stroke crosshead engine with more than one fuel valve in each cylinder. The latter engine typically imposes stringent requirements regarding the long life of the nozzle. Among other reasons, the engine often operates with heavy fuel oil that may even contain sulfur.

The nozzle protrudes through the central hole at the end of the valve housing 2, and the valve housing 2
The annular surface 3 of the cylinder cover shown by a cylinder liner or a broken line so that fuel can be injected when the tip of the nozzle with the nozzle bore 4 protrudes into the combustion chamber A and the fuel valve is opened. Can be pressed against the corresponding abutment surface. The fuel valve has a valve slider 5 with a valve needle 6 and a valve seat 7 arranged at the lower end of the slider guide 8 in the illustrated valve design. The slider guide is pressed against the surface facing the upper side of the nozzle 1.

  The nozzle has a central longitudinal channel 9 from which the nozzle bore 4 is directed to the outer surface of the nozzle. The nozzle is composed of a first material made of a corrosion-resistant first alloy 10 and a second material made of a second alloy. The first alloy constitutes at least the outermost region in the region around the nozzle hole and constitutes the outer surface of the nozzle over the entire portion of the nozzle protruding from the valve housing 2.

The first material consisting of the corrosion-resistant first alloy may be made from a particulate starting material or may be made, for example, by casting. An example of an applicable alloy for use as the first alloy is a nickel-based alloy. This alloy may, for example, typically contain 15 to 30% Cr, 0.02 to 0.55% C, and optionally one or more of the following components, excluding impurities that occur: May be included. 0 to 15% W, 0 to 8% Al, 0 to 5% Ti, 0 to 20% Co, 0 to 2% Hf, 0 to 5% Nb and / or Ta, 0 to 35% Mo, 0-10% Si, 0-1.5% Y, and 0-20% Fe. This alloy contains inevitable impurities, the rest being nickel. A typical example of such an alloy has the following analytical results. That is, 23% Cr, 7% W, 5.6% Al, 1% Si, 0.5% C, and 0.4% Y. This HIP-treated alloy has a fatigue strength σ _A of about ± 450 MPa.

  Nickel-based alloys typically include 35 to 60% Cr, 0.02 to 0.55% C, and optionally one or more of the following components, apart from impurities that occur: The thing of the kind to include may be sufficient. That is, 0 to less than 1.0% Si, 0 to 5.0% Mn, 0 to 5.0% Mo and / or W, 0 to less than 0.5% B, 0 to 8.0% Al, 0 to 1.5% Ti, 0 to 0.2% Zr, 0 to 3.0% Nb, 0 to max 2% Hf, 0 to 1% N, 0 to max 1. 5% Y and up to a total of 5.0% Co and Fe. This alloy contains inevitable impurities, the rest being Ni. This material has high fatigue strength and very high resistance to both hot corrosion and erosion from the fuel.

  Other examples of alloys for use as a corrosion resistant first alloy material are listed in Table 1.

  The coefficient of thermal expansion is described above as the average linear coefficient of thermal expansion for heating at 20 ° C. to 500 ° C., ie it is related over the range of 500 ° C. The first alloy preferably has substantially the same coefficient of thermal expansion as the second alloy. As an alternative, the first alloy suitably has a higher coefficient of thermal expansion than the second alloy so that compressive stress is generated in the central region of the nozzle in connection with cooling from the HIP temperature to 20 ° C. Can do.

Cobalt based alloys such as Celsit 50-P can also be used, but under HIP processing conditions they can only obtain a fatigue strength σ _A of about ± 150 MPa, and for this reason they Is not a preferred material.

  The alloy material for the second alloy is preferably an iron-based alloy, for example 0.4% C, 1.0% Si, 0.4% Mn, 5.2% Cr, 1% V, 1. Tool steel AISI H13 analyzed with 3% Mo and the remainder Fe, or 0.45% C, 0.4% Si, 0.4% Mn, 4.5% Co, 4.5% Cr , 0.5% Mo, 2% V, 4.5% W, and the tool steel AISI H19, which is analyzed as Fe, or U. S. A. Tool steels CPM1V and CPM3V obtained from crucible steel research. CPM1V is 0.5% C, 4.5% Cr, 1% V, 2.75% Mo, 2% W, 0.4% Si, 0.5% Mn, and the rest is Fe. 0.8% C, 7.5% Cr, 2.5% V, 1.3% Mo, 0.9% Si, 0.4% Mn and the balance are Fe.

  Tool steel can be produced by powder metallurgy as a fine-grained isotropic powder with a very fine structure so that a carbide network is avoided, despite the high proportion of added alloy components. By pressure spraying the molten alloy into the low temperature atmosphere, the carbide becomes very small and becomes uniformly dispersed.

  Other examples of alloy materials for the second alloy are shown in Table 2, where the coefficient of thermal expansion is described in the same manner as Table 1.

  For a particular tool steel, the fatigue strength can be adjusted using a heat treatment applied to the nozzle blank. After the isotropic pressing process of the nozzle blank part, the outer shape and the inner shape of the nozzle blank part are finished. The longitudinal central channel and nozzle bore may be machined into the blank portion and the outer surface of the blank portion may be turned to its finished shape and polished.

When the shape machining is finished, the nozzle blank portion may be subjected to a heat treatment, which cures the second alloy to an appropriate hardness. The curing step can be performed, for example, at a temperature ranging from 1000 ° C. to 1100 ° C. with an immersion time of 10 minutes to 40 minutes. The final heat treatment is then performed in the form of one or more tempering processes. This tempering is important for the fatigue strength as a result of the finished nozzle. The tempering step may be performed, for example, at a temperature in the range of 450 ° C. to 600 ° C. for an immersion time of 2 hours. Preferably, a double or triple tempering step is used with 2 or 3 cycles of 2 hours. The tool steel described above may have a fatigue strength σ _A of about ± 500 to 900 MPa in the finished nozzle. Preferably, the fatigue strength σ _A is at least ± 750 MPa. At the same time, the tool steel advantageously has a high wear resistance and hardness.

For both the first and second alloys, suitably used powders have a size in the range of 0 to 1000 μm.
An example is given below to show how the nozzle blank part can be processed in an isotropic pressing process.

  FIG. 2 shows the preformed core member 12 inserted into the mold 13, which is constructed from a bottom panel 14, a side wall 15, a cover 16 and a filling nozzle 17. The core member is made of a second alloy and is pre-made from powder that has been sintered together and cold pressed into a so-called green blank. The core member may be made by high speed powder pressing or by a CIP or HIP process. The core member may be made by conventional methods for tool steel and may be ESR (Electronic Slag Refining) recast. The core member has a head section 18 with a substantially larger diameter than the body section 10 projecting upward into the mold 13. The body section may end at a constant distance from the nozzle bore, or it may extend further into the nozzle to cover the entire central channel, as shown in FIG. In the latter case, the nozzle bore passes through the second alloy in the region around the central channel and passes through the first alloy in the outermost region of the nozzle.

  The side wall 15 fits around the head section 18 and narrows to a smaller diameter as it goes up. Around the body section, the side walls are separated by a distance that generally corresponds to the desired thickness of the corrosion-resistant first alloy. The circular bottom panel 14 is welded to the lower rim of the side wall 15 along its entire circumference. Similarly, the cover 16 is welded to the upper rim of the side wall and the filling nozzle is welded to the upper surface of the cover.

  The finely granulated powder of the first alloy 10 is filled into the cavity around the core member 12 through the filling nozzle 17. The mold containing the powder is vibrated and a post-filling step of more powder is performed, and if necessary, the mold is aspirated and closed in a pressure-tight state with a filling nozzle.

  The mold is then placed in a furnace and the furnace chamber is pumped with an inert gas such as argon to a pressure of about 200 bar and heated to a temperature in the range of 1000 to 1300 ° C, typically 1150 ° C. The Simultaneously with heating, the pressure in the furnace chamber rises to about 900 to about 1100 bar. Temperature and pressure are maintained for a period of 4 to 8 hours, during which time the material in the mold solidifies into a dense body without pores.

  The mold is removed from the HIP processing blank after cooling. The used mold may be made, for example, from steel or glass. In the latter case, the welding described above consists in melting and heating the glass.

  The annealed nozzle blank portion is then machined to its finished shape, for example by lathe or drilling, which can relieve the stress, harden and temper the blank portion. If the nozzle heat treatment occurs at a temperature below the HIP temperature as a result of the high temperature HIP treatment, the nozzle heat treatment can be performed with virtually no particle growth in the material. This is an advantageous advantage. This is because larger particles produce lower fatigue strength.

  The lifetime of the nozzle according to the present invention is long. Especially because there are no microcracks in the transition region between the two materials. A microcrack is a crack in a single crystal grain or a crack that extends through several crystal grains. Microcracks can typically have a length range of 0.05 mm to 0.5 mm. Cracks with a size smaller than 0.05 mm can be ignored. When microcracks occur in the nozzle, there are many cracks in the nozzle. The reason is that cracks caused by the above-mentioned heat-affected areas or by coupling errors affect a large area, not just a few particles. Thus, the presence of microcracks can be determined by examining the boundary area exposed to some stress between the two alloys in the nozzle. If most of the exposed area is free of microcracks, all nozzles can be considered free of microcracks in the boundary area.

For simplicity, the following description of other examples utilizes the same reference numbers as used above for details having the same function.
FIG. 3 shows a mold 13 design that is suitable for the production of multiple nozzle blanks in the same mold. The side wall 15 is cylindrical with an inner diameter corresponding to the outer diameter of the head section 18. The thickness of the first alloy is controlled by placing a cylindrical filling pipe 21 around the body section before filling the pipe with powder. By making the side wall 15 longer than that shown in the figure, the first core member 12, the diffusion barrier 24 linked thereto, and the filling pipe 21 are arranged in the side wall before the cover 16 is attached. Can thereby fill the powder into the filling pipe to its upper edge. Next, the middle rear member with the pipe 21, the barrier 24, and the powder can be placed on top of the first placed until it reaches the top of the side wall 15, and the entire mold is attached to the cover 16. Closed. Next, the HIP process is executed as described above.

  The diffusion barrier 24 is disposed on the outer surface of the body section 19 and on the side facing the upper side of the head section 18. The barrier may be a coating applied to a preformed core member by electrolyte deposition or other surface treatment methods such as plating. The barrier may be made of, for example, nickel, copper, cobalt, or a nickel-phosphorus alloy. Alternatively, the coating can be applied by spraying or by placing a thin foil of the desired material, typically a pure metal such as nickel, cobalt or copper. The barrier suitably has a thickness in the range of 5 to 400 μm, preferably 10 to 100 μm.

  In FIG. 4, the side wall 15 is cylindrical and welded to the shoulder of the head section 18 at its lower rim. This design makes the mold cheaper. In connection with the final machining of the nozzle, the welding associated with the heat affected area is removed by a lathe. The preformed core member can be made by, for example, the preceding HIP process or the CIP process (cold isotropic pressing), but the weld cannot be made of the material.

  FIG. 5 shows a design in which a first alloy cylindrical wall 22 is arranged around the body section 19. The inner diameter of the pipe is slightly larger than the outer diameter of the body section so that the diffusion barrier 24 is not damaged during assembly. The wall 22 can be manufactured by powder metallurgy techniques, but can also be manufactured as a common pipe, preferably a seamless pipe. After the first alloy 10 powder is filled inside the wall, the HIP process is performed as described above except that the wall 22 remains on the core member and is part of the nozzle blank portion. Is done.

  FIG. 6 shows a further design in which the first alloy wall 22 is bowl-shaped and equipped with a diffusion barrier 24. After the cover 16 is installed, the mold is filled with the powder of the second alloy and the HIP process is performed as described above except that the wall 22 remains on the HIP manufacturing inner part of the nozzle blank part. Is done.

  Both the corrosion resistant first alloy 11 and the second alloy 11 in the form of the wall 22 are manufactured with the diffusion barrier 24 as two prefabricated members, the barrier of one member or the other member. Arranged in either place, these members are inserted into each other as shown in FIG. 6 to attach the cover 16, and the mold is aspirated and closed, and the HIP process is performed as described above. It becomes possible further. In this case, the HIP process does not include the actual integration step of the particulate material when these members have already been pre-manufactured as described above, but the HIP process does not allow these members to be at the interface. By the diffusion bonding step, solidification into a coherent blank portion is achieved.

  FIG. 7 shows a further embodiment in which the mold is divided internally by a panel partition 23 that extends at the interface between the first and second alloys. The panel partition 23 can be made from a first alloy or a second alloy. The panel partition 23 can also be an oxygen limited diffusion barrier made from a third material. Since the panel partition is relatively thick, components from the second alloy cannot diffuse into the first alloy.

  The bottom panel is equipped with a filling nozzle 17 for filling the powder. The first one powder is filled by the associated filling nozzle, so that air is aspirated and the nozzle is closed. The mold is turned over, the second powder is filled by the second nozzle, and air is aspirated from the second chamber. HIP processing is performed as described above.

  The nozzle may have a different design than that shown in FIG. It is possible to place a second closing member on the valve slider, which closes the nozzle bore 4 downstream of the fuel channel 9. When the second closure member slides along the inner surface of the longitudinal channel, which can also be made from tool steel, the second closure member can advantageously be made from tool steel. This takes advantage of the fact that the two tool steels move well along each other. It is also possible to arrange the main valve seat downstream of the nozzle to minimize the volume of the fuel channel below the valve seat. Furthermore, the nozzle bore can be directed not only on one side of the nozzle but on either one and the other side or distributed along the entire circumference of the nozzle.

  The preformed core member of the second alloy and / or the bowl or pipe-shaped wall of the first alloy is pre-manufactured from a material that is not based on a particulate starting material, such as, for example, a cast or forged material. May be.

  During the HIP process, so that the second material is cured and / or tempered or annealed during or in direct connection with the HIP process, thus omitting the subsequent heat treatment step. It becomes possible to control the temperature.

  The details and examples of the various embodiments can be combined into a new embodiment. It is also possible to mix the powders of the first alloy or the second alloy from a number of powder sizes, and a number of different metal alloy powders which can be of the kind described above can also be used. Furthermore, ceramic powder can be mixed to obtain an insulating effect. The ceramic powder may be placed in the layer at a short distance from the tip of the nozzle. The ceramic powder is covered with a powder of the first corrosion resistant alloy. It is also possible to use stepwise mixing of various powders. Furthermore, it is possible to place a screen of ceramic material in the first alloy powder, for example the powder present above the body section 19 in FIG. Become. The first alloy powder is placed on top of the screen so that the outermost of the nozzle is made of a corrosion resistant material.

FIG. 1 is a longitudinal sectional view of a nozzle attached to the lowermost end of a fuel valve. FIG. 2 shows a cross-sectional view of a mold filled with various powders for use in HIP processing of nozzles. FIG. 3 shows a cross-sectional view of a mold filled with various powders for use in HIP processing of nozzles. FIG. 4 shows a cross-sectional view of a mold filled with various powders for use in HIP processing of nozzles. FIG. 5 shows a cross-sectional view of a mold filled with various powders for use in HIP processing of nozzles. FIG. 6 shows a cross-sectional view of a mold filled with various powders for use in HIP processing of nozzles. FIG. 7 shows a cross-sectional view of a mold filled with various powders for use in HIP processing of nozzles.

Claims (19)

A method of manufacturing a nozzle for a fuel valve in a diesel engine, in particular a two-stroke crosshead engine, wherein a first material of a corrosion-resistant first alloy has an outer surface of the nozzle around the nozzle bore. To be arranged in the template at least in the outer region,
The second material of the second alloy is arranged in the inner region in the mold, and the material arranged as described above is obtained by the isotropic pressing step, the first alloy and the second alloy. Processed into a solidified nozzle blank part where no microcracks are present in the boundary region between the two.   The method of claim 1, wherein the second material of the second alloy has a higher fatigue strength in the finished nozzle than the first alloy that is resistant to corrosion.   When at least the corrosion resistant alloy contains more than 0.6% Al, an oxygen limited diffusion barrier is used between the first material and the second material before the isotropic pressing step. The method according to claim 1 or 2, characterized in that:   The method of claim 3, wherein the diffusion barrier comprises nickel, copper, or a nickel alloy.   The diffusion barrier is disposed on an inner surface of a prefabricated member of the first material or on an outer surface of a prefabricated member of the second material. Item 5. The method according to Item 3 or 4.   6. A prefabricated member of the first material is preferably filled with a granular starting material of the second alloy using a high speed powder pressing process. The method according to claim 1.   The prefabricated member of the first alloy is cast or manufactured into a bowl shape or tubular wall by powder metallurgy technology to form part of a mold used in the isotropic pressing process. The method of claim 6, characterized in that:   A preformed core member of the second material is placed in a mold, in which the granular starting material of the first alloy is arranged before the isotropic pressing step is performed. 6. A method according to any one of claims 1 to 5, characterized in that   The pre-formed member of the first material and / or the pre-formed member of the second material can be a high speed powder press, for example, where a work process or extrusion can be subsequently performed. 9. A process according to claim 6, characterized in that it is produced from a granular starting material using a process, CIP process or HIP process, or using a sintering process where the next process is a pressing process. The method according to claim 1.   The method according to any one of claims 1 to 9, wherein the isotropic pressing step is a HIP process. A nozzle for a fuel valve in a diesel engine, in particular a two-stroke crosshead engine,
The nozzle has a central longitudinal bore in communication with a number of nozzle bores that open at the outer surface of the nozzle;
The nozzle is made of a first alloy that is corrosion resistant at least in the outer region around the nozzle bore and is made of a second alloy in a region different from the outer region;
The nozzle in the boundary region between the first alloy and the second alloy has a structure free from microcracks.   The nozzle according to claim 11, wherein the second alloy has higher fatigue strength than the corrosion-resistant first alloy.   The nozzle according to claim 11 or 12, wherein an oxygen-limited diffusion barrier is provided between the first alloy and the second alloy in the nozzle.   The nozzle according to claim 11, wherein the second alloy is made by powder metallurgy technology.   15. The nozzle according to any one of claims 11 to 14, wherein the first alloy is a nickel-based alloy and the second alloy is an iron-based alloy.   16. Nozzle according to any one of claims 11 to 15, characterized in that the nozzle is a separate unit arranged in the fuel valve with an extension of a spindle guide containing the main valve seat of the fuel valve. .   The nozzle according to claim 16, wherein the second alloy occupies more than 70% of the total mass of the nozzle. The nozzle according to any one of claims 11 to 17, wherein the fatigue strength σ _A of the second alloy is at least ± 750 MPa.   19. A nozzle according to any one of claims 11 to 18, wherein an insulating ceramic material covered by the first alloy is provided in the nozzle.

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