JP6065389B2 - Thermal insulation structure and manufacturing method thereof - Google Patents

Description

  The present invention relates to a heat insulating structure including a thermal spray coating formed on a substrate surface and a method for manufacturing the same.

As for the heat insulating structure formed on the substrate surface, in the 1980s, as a method for increasing the thermal efficiency of the engine, it was proposed to provide a heat insulating layer on the part facing the engine combustion chamber (for example, Patent Document 1). A heat insulating layer made of a ceramic sintered body and a heat insulating layer made of a thermal spray layer containing ZrO ₂ particles having low thermal conductivity have been proposed.

  However, ceramic sintered bodies faced problems such as generation of cracks due to thermal stress and thermal shock, and generation of cracks. For this reason, in particular, a structure in which a heat insulating layer made of a ceramic sintered body is applied to portions having a relatively large area such as the top surface of the piston, the inner peripheral surface of the cylinder liner, and the lower surface of the cylinder head has not been put into practical use.

On the other hand, the sprayed layer itself has been used for trochoidal surfaces of cylinder liners and rotary engines, but this is intended to improve wear resistance and not to improve heat insulation. Absent. Thus, in order to make the thermal spray layer a heat insulating layer, it is preferable to spray a low thermal conductive material mainly composed of ZrO ₂ (zirconia) as described above, but the zirconia-based layer is more preferable than the cermet-based layer. However, the adhesion between the particles is inferior, and there is a problem that cracks are likely to occur due to fatigue due to thermal stress or repeated stress.

  In order to solve such a problem, for example, Patent Document 2 proposes a structure in which particles and reinforcing fiber materials are included in a heat insulating thin film.

International Publication No. 89/03930 Pamphlet JP 2009-243352 A

  The above-mentioned Patent Document 2 does not describe in detail the method for obtaining the heat insulating thin film only by the description of coating or bonding, but for the purpose of containing particles and ensuring heat insulating properties. In view of this, it can be considered that the heat insulating thin film is somewhat porous (porous). Then, when the heat insulation thin film of patent document 2 is provided, for example in the top surface of a piston, the fuel injected from the fuel injection valve will permeate into the surface of the heat insulation thin film (it will be taken in into a pore part). Therefore, the unburned loss ratio increases, which may lead to a decrease in thermal efficiency.

  This invention is made | formed in view of this point, The place made into the objective is heat insulation in a heat insulation structure provided with a thermal spray coating formed on the base-material surface, and its manufacturing method, improving heat insulation. The object is to provide a technique for suppressing the penetration of fuel or the like into the structure.

In order to achieve the above object, in the heat insulating structure and the manufacturing method thereof according to the present invention, the thermal spray coating for enhancing the thermal insulation including the ZrO ₂ -containing particles and the pores is formed by a finer thermal spray coating than this. It is trying to seal.

  Specifically, the first invention is directed to a heat insulating structure including a thermal spray coating formed on the surface of a base material.

The sprayed coating was sprayed on the first oxide layer including the hollow ZrO ₂ -containing particles sprayed on the substrate and flattened, and the pores, and the first oxide layer. Including oxide particles whose main component is one selected from the group consisting of Al ₂ O ₃ , SiO ₂ and ZrO ₂ having a particle size smaller than that of the ZrO ₂ -containing particles of the first oxide layer And a second oxide layer.

According to the first invention, the pores contained in the first oxide layer are sealed by the second oxide layer, which is a dense sprayed layer, provided on the surface of the first oxide layer. When the heat insulating structure is applied to, for example, the top surface of the piston, the inner peripheral surface of the cylinder liner, the lower surface of the cylinder head, etc., the sprayed fuel soaks into the first oxide layer (into the pores). Can be suppressed). Further, since the ZrO ₂ -containing particles of the first oxide layer are flat hollow particles, the first oxide layer contains more air with low thermal conductivity than when solid particles are sprayed. Therefore, the heat insulation can be improved.

In a second aspect based on the first invention, the oxide particles of the upper Symbol second oxide layer is characterized in that a medium circumstances particles.

According to the second invention, since the oxide particles of the second oxide layer are solid particles, it is difficult for pores to be formed in the surface portion of the heat insulating structure, so that the sprayed fuel or the like is the first oxide. It is possible to further suppress the penetration into the layer.

  The third invention is directed to a method for manufacturing a heat insulating structure including a thermal spray coating formed on the surface of a base material.

Then, as spraying material, and ZrO ₂ containing particles having an average particle diameter _{D 50} is 30 to 100 [mu] m, an average particle diameter _{D 50} is 5~40μm and than the average particle diameter _{D 50} of the ZrO ₂ containing particles that And an oxide particle mainly composed of one selected from the group consisting of Al ₂ O ₃ , SiO ₂ and ZrO ₂ having a small average particle diameter D ₅₀ , and the ZrO ₂ -containing particles as the base material On the other hand, thermal spraying is performed at a predetermined spraying output, a predetermined Ar gas flow rate, a predetermined H ₂ gas flow rate, a predetermined spraying distance, and a predetermined sprayed particle supply amount, and includes the ZrO ₂ -containing particles and pores. A step of forming a first oxide layer, a spraying power higher than the predetermined spraying power for the oxide particles to the first oxide layer, a spraying distance longer than the predetermined spraying distance, and More than the predetermined sprayed particle supply amount Spraying with a small supply amount to form a second oxide layer.

According to the third aspect of the invention, since the oxide particles are sprayed at a spraying distance longer than a predetermined spraying distance when forming the first oxide layer, the second oxide layer is made uniform (thickness is made uniform). Can be formed). Then, when the spraying distance is separated, the force for spraying the oxide particles to the first oxide layer is weakened, but with a spraying power higher than a predetermined spraying power when forming the first oxide layer, Since the oxide particles are thermally sprayed, the second oxide layer can be reliably formed while suppressing unevenness due to a decrease in output. Further, since the oxide particles are sprayed with a supply amount smaller than a predetermined sprayed particle supply amount when forming the first oxide layer, the second oxide layer can be formed thin. As a result, it is possible to provide the second oxide layer, which is a thin and dense sprayed layer, on the surface portion of the first oxide layer, so that the ZrO ₂ -containing particles and pores in the first oxide layer can be provided. It is possible to suppress the penetration of fuel or the like into the first oxide layer by the dense sprayed layer in the second oxide layer, while improving the heat insulating property by the portion. The reason for the range of the average particle diameter _{D 50} of the ZrO ₂ containing particles 30 to 100 [mu] m (30 [mu] m or 100μm or less), when less than 30 [mu] m, the size of the pores formed between the ZrO ₂ containing particles This is because there is a concern about a decrease in the heat insulating property, and it is necessary to make the material of the second oxide layer sprayed so as to close the pores, and it is difficult to classify the material. On the other hand, if it exceeds 100 μm, the pores become large, and not only the strength of the oxide layer is lowered, but also the amount of raw material for forming the second oxide layer must be increased. On the other hand, the reason why the average particle diameter D ₅₀ of the oxide particles for forming the second oxide layer in the range of 5 to 40 m (5 [mu] m or more 40μm or less) is the less than 5 [mu] m formed on the first oxide layer This is because the number of spraying passes to close the pores and to secure the film thickness increases, and it takes time to manufacture, and if it exceeds 40 μm, it cannot enter the pores of the first oxide layer. This is because it becomes difficult to prevent the infiltration of fuel.

According to the heat insulating structure according to the present invention, provided on the surface portion of the first oxide layer, the second oxide layer is a dense sprayed layer, pore portions included in the first oxide layer sealing Therefore, it is possible to suppress the penetration of fuel or the like into the heat insulating structure , and the ZrO ₂ -containing particles of the first oxide layer are flat hollow particles, so that the heat insulating property can be improved. can Ru. According to the method for manufacturing a heat insulating structure according to the present invention, it is possible to provide the second oxide layer, which is a thin and dense thermal sprayed layer, on the surface portion of the first oxide layer. It is possible to suppress the penetration of fuel or the like into the first oxide layer by the dense sprayed layer in the second oxide layer while enhancing the heat insulating property by the ZrO ₂ -containing particles and the pores in the one oxide layer.

1 is a cross-sectional view showing an engine structure according to Embodiment 1. FIG. It is a graph which shows the relationship between the geometric compression ratio of the engine from which specifications differ, and an illustration thermal efficiency. It is a graph which shows the relationship between the excess air ratio (lambda) of the engine from which a specification differs, and illustration thermal efficiency. It is sectional drawing which shows the heat insulation film structure of an aluminum alloy piston. It is an expanded sectional view which shows typically the thermal spray coating of the piston. It is a figure which shows the unburned loss ratio (%) of Examples 1-6 and a comparative example.

  Hereinafter, embodiments of the present invention will be described in detail with reference to the drawings.

  In this embodiment, the heat insulating structure according to the present invention is employed in the piston of the engine shown in FIG.

<Engine features>
This engine is an in-line four-cylinder 2L gasoline engine. Reference numeral 3 in FIG. 1 is a cylinder block, reference numeral 5 is a cylinder head, reference numeral 7 is an intake valve for opening and closing the intake port 9, and reference numeral 11 is an exhaust port 13. Reference numeral 15 denotes an exhaust valve that opens and closes the fuel injection valve. The combustion chamber of the engine is formed by the top surface of the piston 1, the inner peripheral surface of the cylinder block 3, the lower surface of the cylinder head 5, and front surfaces of the umbrella portions of the intake and exhaust valves 7 and 11 (surfaces facing the combustion chamber). A cavity 17 is formed on the top surface of the piston 1. In FIG. 1, the ignition plug is not shown.

  By the way, it is known that the thermal efficiency of the engine theoretically increases as the geometric compression ratio increases and the excess air ratio of the working gas increases. As the excess air ratio is increased and the excess air ratio is increased, the cooling loss, which is the energy taken away as heat to the outside, increases. Therefore, the improvement of the thermal efficiency due to the increase in the compression ratio and the excess air ratio reaches its peak.

  That is, the cooling loss depends on the heat transfer rate from the working gas to the engine combustion chamber wall, its heat transfer area, and the temperature difference between the gas temperature and the wall temperature, and the heat transfer rate depends on the gas pressure and temperature. Therefore, if the gas pressure and temperature increase due to the increase in the compression ratio and excess air ratio, the heat transfer rate increases and the temperature difference between the wall temperature and the gas temperature increases, resulting in a large cooling loss. Become. For this reason, at present, it is not possible to achieve an ultra-high compression ratio of 20 or more due to cooling loss.

  In turn, the engine of the present embodiment is a lean burn engine that has a geometric compression ratio ε = 20 to 50 and is operated at an excess air ratio λ = 2.5 to 6.0 at least in a partial load region. . Therefore, in order to obtain the desired thermal efficiency commensurate with the compression ratio ε and excess air ratio λ, the engine heat loss must be increased unless the engine cooling loss is significantly reduced. In order to explain this point on the basis of the thermal efficiency shown in the model calculation, when the compression ratio ε is increased, whether the combustion chamber has a heat insulating structure or not, and whether the excess air ratio λ is large or small, A model calculation was performed to see how it is affected.

  FIG. 2 shows the result. In the figure, “without heat insulation” means a conventional engine that does not employ a heat insulation structure in the combustion chamber, and “with heat insulation” means that the combustion chamber is more than a conventional engine that does not employ a heat insulation structure in the combustion chamber. This means an engine with a 50% higher heat insulation rate. “200 kPa” and “500 kPa” represent the magnitude of the engine load.

  First, in the case of “no heat insulation 200 kPa λ = 1”, the indicated thermal efficiency increases as the compression ratio ε increases. However, even if the compression ratio ε = 50 is exceeded, the indicated thermal efficiency does not greatly improve, and the compression ratio ε Since the theoretical efficiency at = 50 is about 80%, the indicated thermal efficiency of the engine is considerably low. Most of this difference is cooling loss and exhaust loss.

  In the case of “without heat insulation 200 kPa λ = 2”, the specific heat ratio decreases due to an increase in the excess air ratio, so that the illustrated thermal efficiency is high, but it is still low in terms of theoretical efficiency. Looking at “without heat insulation 200 kPa λ = 4” and “without heat insulation 200 kPa λ = 6”, when the compression ratio ε exceeds 15 or 25, the indicated thermal efficiency decreases as the compression ratio ε increases. This is because the excess air ratio λ is large (the air density of the air-fuel mixture is high), so when the compression ratio is high, the gas pressure during combustion becomes very high, and the heat transfer coefficient as a function of the gas pressure and temperature is high. This is because the cooling loss increases. That is, the cooling loss becomes larger than the increase in thermal efficiency due to the increase in excess air ratio λ (increase in specific heat ratio).

  On the other hand, in the case of “with heat insulation 200 kPa λ = 2.5”, the indicated thermal efficiency increases as the compression ratio ε increases. In the case of “with heat insulation 200 kPa λ = 6” in which the excess air ratio λ is increased, when the compression ratio ε exceeds 40, the illustrated thermal efficiency slightly decreases, but the illustrated thermal efficiency is very high at the compression ratio ε = 20 to 50 It is a value. Even in the case of “with heat insulation 500 kPa λ = 2.5” in which the engine load is increased, the indicated thermal efficiency is high at the compression ratio ε = 20-50.

  FIG. 3 is a graph showing the relationship between the excess air ratio λ and the indicated thermal efficiency. In the case of “no heat insulation 200 kPa ε = 15”, the illustrated thermal efficiency peaks near the excess air ratio λ = 4.5, and the illustrated thermal efficiency decreases as the excess air ratio λ increases. On the other hand, in the case of “with heat insulation 200 kPa ε = 40”, the illustrated thermal efficiency peaks in the vicinity of the excess air ratio λ = 6.0. This is because the compression ratio ε is high and the cooling loss is suppressed by heat insulation.

  In the case of the lean burn engine, it operates at an excess air ratio λ = 2.5 or more at least in the partial load region, which is advantageous for suppressing NOx generation. As the compression ratio ε increases, the combustion temperature increases. However, by controlling the excess air ratio λ so as to increase as the engine load increases, NOx generation is prevented so that the maximum combustion temperature does not exceed 1800 (K). Can be suppressed.

  Although not shown, an intercooler that cools the intake air is provided in the intake system of the engine. As a result, the in-cylinder gas temperature at the start of compression is lowered, the increase in gas pressure and temperature during combustion is suppressed, and this is advantageous in reducing cooling loss (improving the indicated thermal efficiency).

<Insulation structure>
Therefore, in the following, in order to reduce the cooling loss necessary for increasing the indicated thermal efficiency in an engine operated at the above-mentioned ultra-high compression ratio ε = 20 to 50 and high excess air ratio λ = 2.5 to 6.0 The heat insulation structure will be described. FIG. 4 is a sectional view showing a heat insulating structure of the piston. The piston 1 includes a thermal spray coating 21 on a top surface forming a combustion chamber of the engine. The thermal spray coating 21 includes an undercoat 23 formed over the entire top surface of the piston base material 19 and the undercoat 23. A first oxide layer 25 covering the coat 23 and a second oxide layer 27 covering the first oxide layer 25 are provided.

The piston base material 19 can be formed by, for example, an aluminum alloy AC8A for casting (thermal conductivity: 141.7 (W / (m · K)), specific heat capacity: 2300 (kJ / (m ³ · K))). it can. The piston base material 19 may be formed of other aluminum alloy or a cast iron piston.

The undercoat 23 plays a role of improving the adhesion of the first oxide layer 25 to the piston base material 19 and reducing the difference in thermal expansion between the oxide layers 25 and 27 and the piston base material 19. The Ni—Cr alloy is formed with a thickness of about 100 (μm) by plasma spraying the top surface of the piston base material 19. As the Ni—Cr alloy, for example, a Ni-20Cr alloy (thermal conductivity: 12.6 (W / (m · K)), volume specific heat: 3660 (kJ / (m ³ · K))) is employed. be able to.

As shown in FIG. 5, the first oxide layer 25 is formed from a large number of zirconia particles (ZrO ₂ -containing particles) 29 sprayed on the top surface of the piston base material 19 and from the surface to the inside of the oxide layer. The pore portion (void) 31 is included.

As the material of the zirconia particles 29, for example, partially stabilized zirconia (ZrO ₂ —Y ₂ O ₃ ) using yttria as a stabilizer can be used, and the zirconia particles 29 as the spraying raw material have an average particle diameter D. It is formed in a substantially hollow sphere with ₅₀ being 70 μm. Thus, the first oxide layer 25 is formed by spraying the zirconia particles 29 on the top surface of the piston base material 19 that has been subjected to the undercoat treatment using a plasma spraying device, and softening the zirconia particles 29 by the thermal spraying heat. By colliding with the piston base material 19 and deforming and accumulating in a flat shape, it is formed into a porous material having a thickness of about 900 (μm) and a porosity of 13 (vol%). In addition, the porosity of the 1st oxide layer 25 can be adjusted by adjusting the particle size and spraying speed of the zirconia particle 29, 5-40 (vol%) is preferable and 10-25 (vol%) is preferable. More preferred. The size of each pore 31 is preferably 1 to 100 (μm). Incidentally, the measurement of the average particle diameter D ₅₀ can be used Shimadzu Corporation Seisakusho laser diffraction particle size distribution measuring apparatus.

Here, the spraying conditions vary depending on the spraying apparatus to be used. For example, when an F4 type plasma spraying gun manufactured by Sulzer Metco is used, the output is 25 to 50 (kW), and the Ar gas flow rate is 35 to 35. _{50 (L / min), H} 2 gas flow rate 10~20 (L / min), spray distance 50 to 150 (mm), spray particle supply amount 20~50 (g / min) is preferred.

  Thus, in order to improve heat insulation, partially stabilized zirconia having a lower thermal conductivity than the piston base material 19 is used as the coating material, and the first oxide layer 25 is made porous with a porosity of 13 (vol%). By forming, the thermal conductivity of the thermal spray coating 21 becomes 0.8 (W / (m · K)). However, when such a porous sprayed coating 21 is formed on the top surface of the piston 1, the gasoline soaks into the sprayed coating 21 when a mixture of gasoline (fuel) and air is sprayed into the combustion chamber. (Incorporated into the pores 31), the unburned loss ratio increases, which may lead to a decrease in thermal efficiency.

Therefore, in the insulating structure of the present embodiment, the surface of the first oxide layer 25, the average particle diameter D ₅₀ than the average particle diameter D ₅₀ of the zirconia particles 29 of the first oxide layer 25 is small, Al _{A second} oxide layer 27 containing oxide particles mainly composed of one selected from the group consisting of ₂ O ₃ , SiO ₂ and ZrO ₂ is formed. These Al ₂ O ₃ , SiO _2, and ZrO ₂ as the thermal spraying raw material have an average particle diameter D ₅₀ of 20 μm, and are formed in a substantially solid spherical shape that is smaller than the average particle diameter D ₅₀ of the zirconia particles 29. . Thus, since the second oxide layer 27 is only for suppressing gasoline from entering the first oxide layer 25, it is desirable that the second oxide layer 27 is free from spots and thin.

  For this reason, in the heat insulation structure of this embodiment, when forming the 2nd oxide layer 27, it is a thermal spray output higher than the predetermined thermal spray output at the time of forming the 1st oxide layer 25, and 1st The oxide particles are sprayed at a spraying distance longer than the predetermined spraying distance when the oxide layer 25 is formed and at a supply amount smaller than the predetermined spraying particle supply amount when the first oxide layer 25 is formed. Thermal spraying is performed on the surface of the first oxide layer 25. In other words, by spraying at a long spraying distance, the second oxide layer 27 is formed without unevenness (with a uniform thickness), and the spraying force is weakened when the spraying distance is separated, but spraying with a high spraying output. Thus, the second oxide layer 27 is thinly formed by suppressing the spots due to the decrease in output and spraying with a small amount of sprayed particles.

<Method of manufacturing a heat insulating structure>
The piston 1 having the heat insulation structure can be obtained by the following method.

First, for example, Ni-20Cr alloy is plasma sprayed on the top surface of the piston base 19 using the F4 type plasma spray gun, for example, to form an undercoat 23 having a thickness of about 100 (μm). Then, using the same F4 type plasma spray gun, the top surface of the piston base material 19 that has been subjected to the undercoat treatment under predetermined spraying conditions is made of the above partially stabilized zirconia (ZrO ₂ —Y ₂ O ₃ ). Then, approximately hollow spherical zirconia particles having an average particle diameter D ₅₀ of 70 μm are plasma sprayed to form an oxide layer having a thickness of about 900 (μm) and a porosity of 13 (vol%). Then, using the same F4 type plasma spray gun, the first spray layer 25 has a higher spray output, a longer spray distance, and a smaller spray particle supply amount than the predetermined spray conditions when the first oxide layer 25 is formed. on the surface of the first oxide layer _25, as a main component one selected from the group consisting of Al ₂ O 3, SiO ₂ and ZrO _2, the average particle diameter _{D 50} is 20 [mu] m, an oxide of solid spherical in substantially The particles are plasma sprayed to form a second oxide layer 27 having a thickness of about 50 (μm).

<Improvement effect of suppression of fuel penetration>
In order to confirm the improvement effect of the fuel penetration control by the heat insulating structure according to the present embodiment, the unburned loss ratio (%) is obtained for each of Examples 1 to 6 under predetermined evaluation conditions. The results were compared.

More specifically, first, an Ni-20Cr alloy is sprayed on the top surface of a piston made of an aluminum alloy AC8A for casting using an F4 type plasma spray gun to form an undercoat having a thickness of 100 (μm). Under the spraying conditions of output 35 (kW), Ar gas flow rate 40 (L / min), H ₂ gas flow rate 15 (L / min), spraying distance 100 (mm), sprayed particle supply rate 40 (g / min), Partially stabilized zirconia particles (ZrO ₂ —Y ₂ O ₃ ) having an average particle diameter D ₅₀ of 70 μm formed into a substantially hollow sphere were thermally sprayed to have a porosity of 13 (vol%) and a thickness of 900 (μm). Six samples with the first oxide layer formed thereon were prepared.

Then, using the F4 type plasma spray gun, the surface of the first oxide layer, thermal spraying conditions shown in Table 1, the average particle diameter D ₅₀ is 20 [mu] m, in substantially real-spherical partially stabilized zirconia particles ( ZrO ₂ —Y ₂ O ₃ ) was plasma sprayed to form a second oxide layer having a thickness of 50 (μm). The Ar gas flow rate and the H ₂ gas flow rate were the same as the flow rates when the first oxide layer was formed.

  On the other hand, as a comparative example, a first oxide layer was formed under the same conditions as described above, and a second oxide layer was not formed.

  That is, in Examples 1 to 3, the second oxide layer is formed with a higher spraying output, a longer spraying distance, and a smaller amount of sprayed particles than the spraying condition of the first oxide layer. . On the other hand, Example 4 is the same spraying condition as the spraying condition of the first oxide layer, and Example 5 is a longer spraying distance than the spraying condition of the first oxide layer, and supplies a larger number of sprayed particles. In Example 6, the second oxide layer was formed at a spraying power lower than the spraying condition of the first oxide layer and at a short spraying distance.

  Thus, for these six types of pistons, under the same evaluation conditions, that is, with a displacement of 19988.8 (CC), four cylinders, a compression ratio of 20, an excess air ratio of 2.5, and a rotational speed of 2000 (rpm), Each unburned loss ratio (%) was obtained.

  FIG. 6 is a diagram showing the unburned loss ratio (%) of Examples 1 to 6 and Comparative Example. As shown in FIG. 6, Examples 1 to 3 in which the second oxide layer was formed with a higher spraying output, a longer spraying distance, and a smaller sprayed particle supply amount than the spraying conditions of the first oxide layer. Then, it turns out that the unburned loss ratio is improved as compared with Examples 4 to 6 which do not satisfy these conditions. As a result, the sprayed gasoline is oxidized by forming the second oxide layer with a higher spraying output, a longer spraying distance, and a smaller amount of sprayed particles than the spraying condition of the first oxide layer. It was confirmed that the penetration into the physical layer can be effectively suppressed. Moreover, it has also confirmed that these Examples 1-6 all had a lower unburned loss ratio than a comparative example.

-Effect-
According to the present embodiment, the pore portion 31 included in the first oxide layer 25 is sealed by the second oxide layer 27 that is a dense sprayed layer provided on the surface portion of the first oxide layer 25. Therefore, when the heat insulating structure is applied to the top surface of the piston 1, the inner peripheral surface of the cylinder block 3, the lower surface of the cylinder head 5, etc., the sprayed fuel is applied to the first oxide layer 25. Infiltration can be suppressed.

  Further, since the first oxide layer 25 is sprayed with the zirconia particles 29 made of hollow particles as a raw material, the first oxide layer 25 has a thermal conductivity in the first oxide layer 25 as compared with the case where the solid particles are sprayed. Therefore, the heat insulation can be further improved.

  On the other hand, in the second oxide layer 27, since the oxide particles using solid particles as the raw material are sprayed on the first oxide layer 25, the heat insulating structure is more than that when the hollow particles are sprayed. Since the pores 31 are less likely to be generated on the surface of the body, it is possible to further suppress the sprayed fuel or the like from entering the first oxide layer 25.

  Furthermore, since the oxide particles are sprayed at a spraying distance longer than a predetermined spraying distance when forming the first oxide layer 25, the second oxide layer 27 can be formed without any spots. Then, when the spraying distance is increased, the force for spraying the oxide particles to the first oxide layer 25 is weakened, but the spraying output is higher than the predetermined spraying power when the first oxide layer 25 is formed. Thus, since the oxide particles are sprayed, it is possible to reliably form the second oxide layer 27 while suppressing unevenness due to a decrease in output. Further, since the oxide particles are sprayed with a supply amount smaller than a predetermined sprayed particle supply amount when forming the first oxide layer 25, the second oxide layer 27 can be formed thin. As a result, it is possible to provide the second oxide layer 27, which is a thin and dense sprayed layer, on the surface portion of the first oxide layer 25, so that the zirconia particles 29 in the first oxide layer 25 are provided. It is possible to suppress the penetration of fuel or the like into the first oxide layer 25 by the dense sprayed layer in the second oxide layer 27 while improving the heat insulating properties by the pore portions 31 and the pore portions 31.

(Other embodiments)
The present invention is not limited to the embodiments, and can be implemented in various other forms without departing from the spirit or main features thereof.

  In the above-described embodiment, when the first oxide layer 25 is formed, the spraying distance is longer than the predetermined spraying distance, the spraying power is higher than the predetermined spraying power, and less than the predetermined sprayed particle supply amount. Although the oxide particles are sprayed by the supply amount, the surface of the first oxide layer 25 includes oxide particles having a particle size smaller than the particle size of the zirconia particles 29 of the first oxide layer 25. If the second oxide layer 27 is formed, it is not always necessary to satisfy the above thermal spraying condition.

  Moreover, in the said embodiment, although the Ni-Cr alloy was used as an undercoat, it is not restricted to this, For example, you may use a Ni-Al alloy.

  Furthermore, in the above-described embodiment, the layer thickness of the undercoat 23 is about 100 (μm), the layer thickness of the first oxide layer 25 is about 900 (μm), and the layer thickness of the second oxide layer 27 is about 50. Although (μm), the thickness of the undercoat 23 and the first and second oxide layers 25 and 27 are not particularly limited.

  As described above, the above-described embodiment is merely an example in all respects and should not be interpreted in a limited manner. Further, all modifications and changes belonging to the equivalent scope of the claims are within the scope of the present invention.

  As described above, the present invention is useful for a heat insulating structure having a thermal spray coating formed on a substrate surface, a method for manufacturing the same, and the like.

19 Piston substrate 21 Thermal spray coating 25 First oxide layer 27 Second oxide layer 29 Zirconia particles (ZrO ₂ -containing particles)
31 Pore

Claims (3)

A heat insulating structure provided with a thermal spray coating formed on a substrate surface,
The thermal spray coating is sprayed on the first base layer including the hollow ZrO ₂ -containing particles and the pores which are sprayed and flattened on the base material, and the thermal spray coating is performed on the first oxide layer. A second oxide particle containing oxide particles whose main component is one selected from the group consisting of Al ₂ O ₃ , SiO ₂ and ZrO ₂ having a particle size smaller than that of the ZrO ₂ -containing particles of the first oxide layer; An oxide layer;
A heat insulating structure characterized by comprising: The heat insulation structure according to claim 1,
Oxides of the above Symbol second oxide layer particles, insulating structure, which is a mid circumstances particles. A method for producing a heat insulating structure provided with a thermal spray coating formed on a substrate surface,
As spraying material, average particle and ZrO ₂ containing particle diameter _{D 50} is 30 to 100 [mu] m, an average particle diameter _{D 50} is 5~40μm and the average particle than the average particle diameter _{D 50} of the ZrO ₂ containing particles Oxide particles mainly having one type selected from the group consisting of Al ₂ O ₃ , SiO ₂ and ZrO ₂ having a small diameter D ₅₀ ,
The ZrO ₂ -containing particles are sprayed on the base material with a predetermined spray output, a predetermined Ar gas flow rate, a predetermined H ₂ gas flow rate, a predetermined spray distance, and a predetermined spray particle supply amount, Forming a first oxide layer containing ZrO ₂ -containing particles and pores;
Supplying the oxide particles to the first oxide layer with a thermal spray output higher than the predetermined thermal spray output, a thermal spray distance longer than the predetermined thermal spray distance, and a supply amount less than the predetermined thermal spray particle supply amount Spraying in a quantity to form a second oxide layer;
The manufacturing method of the heat insulation structure characterized by including.

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