JP7452238B2 - Film forming method - Google Patents

Description

The present invention relates to a film forming method using a cold spray method.

A method of manufacturing a sliding member is known in which a valve seat with excellent high-temperature wear resistance can be formed by spraying raw material powder such as metal onto the seating part of an engine valve using a cold spray method ( Patent Document 1).

International Publication No. 2017/022505 pamphlet

Automotive engines are equipped with a plurality of intake valves and exhaust valves due to multi-valve design. Therefore, when forming valve seats on the seating parts of multiple valves by the cold spray method, the cylinder head and the nozzle of the cold spray device are moved relatively, and the multiple seating parts and nozzles are sequentially formed. At the same time, it is necessary to discharge the raw material powder from the nozzle and spray it onto the seating section facing the nozzle.

When a cold spray device stops spraying raw material powder, it requires a waiting time of several minutes before the raw material powder can be stably sprayed again. Therefore, it is desirable to spray the raw material powder as continuously as possible without interruption. However, if the raw material powder is continuously injected, a film may be formed in unintended locations, and the surface of the area to be coated may become rough due to the high speed jetting of the raw material powder. Film formation is performed by attaching a masking member.

Disposable masking members increase costs, so it is preferable to use them as many times as possible; however, if they are used repeatedly, there is a risk that a film will accumulate in specific locations and interfere with the nozzle. Therefore, there is a problem that the frequency of replacing or cleaning the masking member increases.

The problem to be solved by the present invention is to provide a cold spray film forming method that can reduce the frequency of replacing or cleaning the masking member.

The present invention is a masking film forming method in which a film is formed by continuously spraying raw material powder using a cold spray method, and when film forming is performed on multiple workpieces, the relative speed between the workpieces and the nozzle is low. When setting a turning point on the movement trajectory and above the masking member, the turning point on the masking member set for the current work is set for the previous work. The above problem is solved by setting the position at a different position.

According to the present invention, the turning point where the relative speed between the workpiece and the nozzle becomes low in the movement trajectory is set at a different position on the masking member with respect to the current workpiece and the previous workpiece. It is possible to prevent the raw material powder injected into a film from being deposited on a specific location. As a result, the frequency of replacing or cleaning the masking member can be reduced.

FIG. 2 is a cross-sectional view showing a cylinder head in which a valve seat film is formed using the cold spray device according to the present invention. 2 is an enlarged sectional view of the vicinity of the valve in FIG. 1. FIG. 1 is a configuration diagram showing an embodiment of a cold spray device according to the present invention. BRIEF DESCRIPTION OF THE DRAWINGS It is a front view which shows the spray gun of one embodiment of the cold spray apparatus based on this invention. FIG. 5 is a cross-sectional view taken along line V-V in FIG. 4. FIG. FIG. 5 is a front view showing the spray gun of FIG. 4 in an offset state. FIG. 1 is a front view showing a film forming factory including a cold spray device according to the present invention. FIG. 8 is a plan view of FIG. 7; FIG. 3 is a process diagram showing a procedure for manufacturing a cylinder head using the cold spray device according to the present invention. FIG. 2 is a perspective view of a cylinder head blank material on which a valve seat film is formed using the cold spray device according to the present invention. 11 is a cross-sectional view showing the intake port along the line XI-XI in FIG. 10. FIG. FIG. 12 is a sectional view showing a state in which an annular valve seat portion is formed in the intake port of FIG. 11 by a cutting process. 13 is a cross-sectional view showing a state in which a valve seat film is formed on the intake port of FIG. 12. FIG. FIG. 3 is a cross-sectional view showing an intake port on which a valve seat membrane is formed. 10 is a cross-sectional view showing the intake port after the finishing process of FIG. 9. FIG. FIG. 3 is a plan view of the cylinder head blank showing an example of a movement locus when the nozzle of the cold spray device moves over the opening of the port in the film forming method according to the present invention. 17 is a plan view showing a movement locus for one intake port in FIG. 16. FIG. FIG. 17 is a plan view showing another example of a movement locus for one intake port in FIG. 16; FIG. 3 is a cross-sectional view showing the discharge angle of the nozzle with respect to the masking member in the film forming method according to the present invention. FIG. 19B is an enlarged cross-sectional view showing section XX in FIG. 19(B). In the film forming method according to the present invention, (A) is a cross-sectional view showing the discharge angle with respect to the nozzle and the annular valve seat portion, and (B) is a cross-sectional view showing the discharge angle with respect to the nozzle and the masking member. 2 is a graph showing the relationship between the particle velocity of the raw material powder on the discharge surface of the raw material powder and the inclination (discharge angle) of the nozzle in the film forming method according to the present invention.

DESCRIPTION OF THE PREFERRED EMBODIMENTS An embodiment of the present invention will be described below based on the drawings. First, an internal combustion engine 1 equipped with a valve seat membrane to which the cold spray device of this embodiment is preferably applied will be described. FIG. 1 is a sectional view of an internal combustion engine 1, mainly showing the structure around the cylinder head.

Internal combustion engine 1 includes a cylinder block 11 and a cylinder head 12 assembled to the top of cylinder block 11. The internal combustion engine 1 is, for example, an in-line four-cylinder gasoline engine, and the cylinder block 11 has four cylinders 11a arranged in the depth direction of the drawing. Each cylinder 11a accommodates a piston 13 that reciprocates in the vertical direction in the drawing, and each piston 13 is connected to a crankshaft 14 extending in the depth direction in the drawing via a connecting rod 13a.

Four recesses 12b constituting the combustion chambers 15 of each cylinder are formed on the mounting surface 12a of the cylinder head 12 to the cylinder block 11 at positions corresponding to each cylinder 11a. The combustion chamber 15 is a space for combusting a mixture of fuel and intake air, and is composed of a recess 12b of the cylinder head 12, a top surface 13b of the piston 13, and an inner peripheral surface of the cylinder 11a.

The cylinder head 12 includes an intake port 16 that communicates the combustion chamber 15 with one side surface 12c of the cylinder head 12. The intake port 16 has a bent, substantially cylindrical shape, and guides intake air from an intake manifold (not shown) connected to the side surface 12c into the combustion chamber 15. The cylinder head 12 also includes an exhaust port 17 that communicates the combustion chamber 15 with the other side surface 12d of the cylinder head 12. The exhaust port 17 has a bent, substantially cylindrical shape like the intake port 16, and discharges exhaust gas generated in the combustion chamber 15 to an exhaust manifold (not shown) connected to the side surface 12d. Note that the internal combustion engine 1 of this embodiment includes two intake ports 16 and two exhaust ports 17 for one cylinder 11a.

The cylinder head 12 includes an intake valve 18 that opens and closes an intake port 16 with respect to the combustion chamber 15, and an exhaust valve 19 that opens and closes an exhaust port 17 with respect to the combustion chamber 15. Each of the intake valve 18 and the exhaust valve 19 includes round rod-shaped valve stems 18a, 19a, and disk-shaped valve heads 18b, 19b provided at the tips of the valve stems 18a, 19a. The valve stems 18a, 19a are slidably inserted into substantially cylindrical valve guides 18c, 19c assembled to the cylinder head 12. Thereby, each of the intake valve 18 and the exhaust valve 19 becomes movable with respect to the combustion chamber 15 along the axial direction of the valve stems 18a and 19a.

FIG. 2 shows an enlarged view of the communication portion between the combustion chamber 15, the intake port 16, and the exhaust port 17. The intake port 16 includes a substantially circular opening 16a in a portion communicating with the combustion chamber 15. An annular valve seat film 16b that comes into contact with a valve head 18b of the intake valve 18 is formed at the annular edge of the opening 16a. Then, when the intake valve 18 moves upward along the axial direction of the valve stem 18a, the upper surface of the valve head 18b comes into contact with the valve seat membrane 16b, thereby closing the intake port 16. Conversely, when the intake valve 18 moves downward along the axial direction of the valve stem 18a, a gap is formed between the upper surface of the valve head 18b and the valve seat membrane 16b, and the intake port 16 is opened.

Similar to the intake port 16, the exhaust port 17 has a substantially circular opening 17a in a portion communicating with the combustion chamber 15, and an annular opening 17a that contacts the valve head 19b of the exhaust valve 19 at the annular edge of the opening 17a. A valve seat film 17b is formed. Then, when the exhaust valve 19 moves upward along the axial direction of the valve stem 19a, the upper surface of the valve head 19b comes into contact with the valve seat membrane 17b and closes the exhaust port 17. Conversely, when the exhaust valve 19 moves downward along the axial direction of the valve stem 19a, a gap is formed between the upper surface of the valve head 19b and the valve seat membrane 17b, and the exhaust port 17 is opened. Note that the diameter of the opening 16a of the intake port 16 is set larger than the diameter of the opening 17a of the exhaust port 17.

In the four-cycle internal combustion engine 1, only the intake valve 18 is opened when the piston 13 descends, thereby introducing the air-fuel mixture into the cylinder 11a from the intake port 16 (intake stroke). Subsequently, the intake valve 18 and the exhaust valve 19 are closed, and the piston 13 is raised to approximately the top dead center to compress the air-fuel mixture in the cylinder 11a (compression stroke). Then, when the piston 13 reaches approximately the top dead center, the compressed air-fuel mixture is ignited by the spark plug, causing the air-fuel mixture to explode. This explosion causes the piston 13 to descend to the bottom dead center, and converts the explosion into rotational force via the connected crankshaft 14 (combustion/expansion stroke). Finally, when the piston 13 reaches the bottom dead center and starts rising again, only the exhaust valve 19 is opened and the exhaust gas in the cylinder 11a is discharged to the exhaust port 17 (exhaust stroke). The internal combustion engine 1 generates output by repeatedly performing the above cycle.

The valve seat films 16b and 17b are directly formed on the annular edges of the openings 16a and 17a of the cylinder head 12 by cold spraying. The cold spray method is a supersonic flow of working gas with a temperature lower than the melting point or softening point of the raw material powder, and the raw material powder carried by a carrier gas is introduced into the working gas and injected from the nozzle tip to form a solid phase. The raw material powder is made to collide with the base material in its state, and a film is formed by plastic deformation of the raw material powder. Compared to the thermal spraying method, in which the material is melted and attached to the base material, this cold spray method produces a dense film that does not oxidize in the atmosphere, and has less thermal influence on the material particles, suppressing thermal deterioration and forming It has the characteristics of high film speed, thick film formation, and high adhesion efficiency. In particular, since the film formation rate is fast and a thick film can be formed, it is suitable for use as a structural material such as the valve seat films 16b and 17b of the internal combustion engine 1.

FIG. 3 is a diagram schematically showing the cold spray device 2 of this embodiment used for forming the above-mentioned valve seat films 16b and 17b. The cold spray device 2 of this embodiment includes a gas supply section 21 that supplies a working gas and a carrier gas, a raw material powder supply section 22 that supplies raw material powder for the valve seat membranes 16b and 17b, and a raw material powder supply section 22 that supplies raw material powder at a temperature below its melting point. It includes a spray gun 23 that injects a supersonic flow using working gas, and a refrigerant circulation circuit 27 that cools the nozzle 23d.

The gas supply unit 21 includes a compressed gas cylinder 21a, a working gas line 21b, and a carrier gas line 21c. The working gas line 21b and the carrier gas line 21c each include a pressure regulator 21d, a flow rate control valve 21e, a flow meter 21f, and a pressure gauge 21g. The pressure regulator 21d, the flow rate control valve 21e, the flow meter 21f, and the pressure gauge 21g are used to adjust the respective pressures and flow rates of the working gas and carrier gas from the compressed gas cylinder 21a.

A heater 21i such as a tape heater is installed in the working gas line 21b, and the heater 21i heats the working gas line 21b by being supplied with power from the power source 21h via the power supply lines 21j, 21j. . The working gas is heated by the heater 21i to a temperature lower than the melting point or softening point of the raw material powder, and then introduced into the chamber 23a of the spray gun 23. A pressure gauge 23b and a thermometer 23c are installed in the chamber 23a, and the detected pressure and temperature values are output to a controller (not shown) through respective signal lines 23g and 23g, and feedback control of pressure and temperature is performed. served.

On the other hand, the raw material powder supply section 22 includes a raw material powder supply device 22a, a measuring device 22b attached thereto, and a raw material powder supply line 22c. The carrier gas from the compressed gas cylinder 21a passes through the carrier gas line 21c and is introduced into the raw material powder supply device 22a. A predetermined amount of the raw material powder measured by the measuring device 22b is conveyed into the chamber 23a via the raw material powder supply line 22c.

The spray gun 23 injects the raw material powder P transported into the chamber 23a by the carrier gas from the tip of the nozzle 23d as a supersonic flow by the working gas, and causes it to collide with the base material 24 in a solid state or a solid-liquid coexistence state. Then, a film 24a is formed. In this embodiment, the cylinder head 12 is applied as the base material 24, and the raw material powder P is injected onto the annular edges of the openings 16a, 17a of the cylinder head 12 by a cold spray method, thereby forming the valve seat films 16b, 17b. form.

The nozzle 23d includes a flow path (not shown) through which a refrigerant such as water flows. The nozzle 23d includes a refrigerant introduction part 23e at its tip for introducing the refrigerant into the flow path, and a refrigerant discharge part 23f at its base end for discharging the refrigerant in the flow path. The nozzle 23d cools the nozzle 23d by introducing the refrigerant into the flow path from the refrigerant introduction part 23e, flowing the refrigerant into the flow path, and discharging the refrigerant from the refrigerant discharge part 23f.

The refrigerant circulation circuit 27 that circulates refrigerant in the flow path of the nozzle 23d is connected to a tank 271 that stores refrigerant, an introduction pipe 274 connected to the above-mentioned refrigerant introduction part 23e, and is connected to the tank 271 and the nozzle. 23d, a cooler 273 that cools the refrigerant, and a discharge pipe 275 connected to the refrigerant discharge section 23f. The cooler 273 is composed of, for example, a heat exchanger, and cools the refrigerant by exchanging heat between the refrigerant whose temperature has increased by cooling the nozzle 23d and a refrigerant such as air, water, or gas.

The refrigerant circulation circuit 27 sucks the refrigerant stored in the tank 271 by the pump 272, and supplies the refrigerant to the refrigerant introducing portion 23e via the cooler 273. The refrigerant supplied to the refrigerant introduction part 23e flows through the channel in the nozzle 23d from the front end side toward the rear end side, and cools the nozzle 23d by exchanging heat with the nozzle 23d during that time. The refrigerant that has flowed to the rear end of the flow path is discharged from the refrigerant discharge section 23f to the discharge pipe 275 and returns to the tank 271. In this way, the refrigerant circulation circuit 27 cools the nozzle 23d by circulating the refrigerant while cooling it, so that it is possible to suppress the adhesion of the raw material powder P to the injection passage of the nozzle 23d.

The valve seat of the cylinder head 12 is required to have high heat resistance and wear resistance to withstand knocking input from the valve in the combustion chamber 15, and high thermal conductivity to cool the combustion chamber 15. In response to these demands, for example, the valve seat membranes 16b and 17b formed from precipitation hardening copper alloy powder are harder, have better heat resistance and wear resistance than the cylinder head 12 formed from casting aluminum alloy. Excellent valve seats can be obtained.

In addition, since the valve seat membranes 16b and 17b are formed directly on the cylinder head 12, higher thermal conductivity can be obtained compared to conventional valve seats that are formed by press-fitting a separate seat ring into the port opening. Can be done. Furthermore, compared to the case of using a seat ring that is a separate part, it is possible to get closer to the cooling water jacket, and by increasing the throat diameter of the intake port 16 and exhaust port 17 and optimizing the port shape. Secondary effects such as promotion of tumble flow can also be obtained.

The raw material powder P used for forming the valve seat films 16b and 17b is preferably a metal that is harder than an aluminum alloy for casting and that provides the heat resistance, abrasion resistance, and thermal conductivity necessary for the valve seat. For example, it is preferable to use the precipitation hardening type copper alloy described above. Further, as the precipitation hardening type copper alloy, a Corson alloy containing nickel and silicon, chromium copper containing chromium, zirconium copper containing zirconium, etc. may be used. Further, for example, precipitation hardening copper alloys containing nickel, silicon and chromium, precipitation hardening copper alloys containing nickel, silicon and zirconium, precipitation hardening alloys containing nickel, silicon, chromium and zirconium, precipitation hardening alloys containing chromium and zirconium, etc. A hardened copper alloy or the like may also be used.

Further, the valve seat films 16b and 17b may be formed by mixing a plurality of types of raw material powder, for example, a first raw material powder and a second raw material powder. In this case, it is preferable to use a metal for the first raw material powder that is harder than an aluminum alloy for casting and that provides the heat resistance, abrasion resistance, and thermal conductivity necessary for the valve seat. Preferably, a precipitation hardening copper alloy is used. Further, as the second raw material powder, it is preferable to use a metal that is harder than the first raw material powder. For example, alloys such as iron-based alloys, cobalt-based alloys, chromium-based alloys, nickel-based alloys, molybdenum-based alloys, ceramics, etc. may be applied to the second raw material powder. Further, one type of these metals may be used alone or two or more types may be used in an appropriate combination.

A valve seat film formed by mixing a first raw material powder and a second raw material powder that is harder than the first raw material powder has superior heat resistance than a valve seat film formed only from a precipitation hardening copper alloy. properties and abrasion resistance. This effect is achieved because the second raw material powder removes the oxide film existing on the surface of the cylinder head 12 and exposes a new interface, improving the adhesion between the cylinder head 12 and the metal film. This is thought to be for the purpose of It is also considered that the adhesion between the cylinder head 12 and the metal coating is improved due to the anchor effect caused by the second raw material powder sinking into the cylinder head 12. Furthermore, when the first raw material powder collides with the second raw material powder, a part of the kinetic energy is converted into thermal energy, or a part of the first raw material powder is generated in the process of plastic deformation. It is also believed that heat promotes precipitation hardening in a part of the precipitation hardening copper alloy used as the first raw material powder.

In the cold spray device 2 of this embodiment, the cylinder head 12 on which the valve seat films 16b and 17b are formed is fixed to the base 45, and the tip of the nozzle 23d of the spray gun 23 is connected to the opening 16a of the cylinder head 12, The raw material powder is injected by rotating it along the annular edge of 17a. Since the cylinder head 12 is not rotated, it does not require a large occupied space, and since the spray gun 23 has a smaller moment of inertia than the cylinder head 12, it has excellent rotational transient characteristics and responsiveness. However, as shown in FIG. 3, the spray gun 23 is connected to high pressure piping (high pressure hose) that constitutes the working gas line 21b, so when the spray gun 23 is rotated, the hose of the working gas line 21b is Deformation rigidity due to torsion may impede rotational transient characteristics and responsiveness. Therefore, the cold spray device 2 of this embodiment is configured as shown in FIGS. 4 to 8 to improve the transient characteristics and responsiveness of rotation.

4 is a front view showing the spray gun 23 of an embodiment of the cold spray device 2 according to the present invention, FIG. 5 is a sectional view taken along the line V-V in FIG. 4, and FIG. FIG. 7 is a front view showing a film forming factory including the cold spray apparatus 2 according to the present invention, and FIG. 8 is a plan view of FIG. 7.

The cylinder head 12, which is a workpiece, is placed in a predetermined posture on a base 45 of a film-forming booth 42 of a film-forming factory 4 shown in FIGS. 7 and 8. For example, as shown in FIG. 13, the cylinder head 12 is fixed to the base 45 so that the recess 12b of the cylinder head 12 is on the top surface, and the center line of the opening 16a of the intake port 16 or the opening 17a of the exhaust port 17 is The base 45 is tilted so that its center line is vertical.

The film-forming factory 4 includes a film-forming booth 42 for performing film-forming processing and a transport booth 41, and the film-forming booth 42 has a base 45 on which the cylinder head 12 is placed and a spray gun 23 held therein. An industrial robot 25 is installed. A transport booth 41 is provided in front of the film-forming booth 42, and the cylinder head 12 is carried in and out from the outside through a door 43, and the cylinder head 12 is carried in and out between the transport booth 41 and the film-forming booth 42. This is done by the door 44. For example, while a film forming process is being performed on one cylinder head 12 in the film forming booth 42, the cylinder head 12 that has previously been processed is carried out from the transport booth 41. The film forming process using the cold spray device 2 generates noise due to the shock waves of the supersonic flow and scatters the raw material powder, so the film forming process must be performed with the transfer booth 41 installed and the door 44 closed. Other operations can be performed simultaneously with the film forming process, such as transporting the cylinder head 12 after processing and transporting the cylinder head 12 before processing.

The spray gun 23 is rotatably mounted on a base plate 26 fixed to a hand 251 of an industrial robot 25 installed in a film forming booth 42 of a film forming factory 4 shown in FIGS. 7 and 8. The configuration of the spray gun 23 of this embodiment will be described below with reference to FIGS. 4 to 6. First, as shown in FIG. 4, a bracket 252 is fixed to the hand 251 of the industrial robot 25, a base plate 26 is rotatably attached to the bracket 252, and a spray gun 23 is fixed to the base plate 26. .

More specifically, as shown in FIGS. 4 and 5, a bracket 252 is fixed to the hand 251 of the industrial robot 25, the main body of the motor 29 is fixed to this bracket 252, and the drive shaft 291 of the motor 29 is It is connected to the first base plate 261 via a pulley and belt (not shown), and rotates the first base plate 261 relative to the bracket. The motor 29 reciprocates, for example, within a maximum range of 360 degrees. For example, if the drive shaft 291 is rotated 360 degrees clockwise with respect to the opening 16a of one intake port 16, the drive shaft 291 is rotated 360 degrees counterclockwise with respect to the opening 16a of the next intake port 16. Rotate 291 and repeat this from then on.

The base plate 26 consists of a first base plate 261 and a second base plate 262, and these first base plate 261 and second base plate 262 slide in a direction perpendicular to the rotation axis C (left-right direction in FIG. 4) via a linear guide 281. possible. Then, by driving the fluid pressure cylinder 282, the amount of offset of the second base plate 262 with respect to the first base plate 261 is adjusted, and the injection diameter D of the film forming material is set.

A cover 263 is attached to the second base plate 262, and the spray gun 23 is fixed to the lower end of the cover 263. The spray gun 23 is fixed to the second base plate 262 via the cover 263 so that the spray direction of the nozzle 23d is directed toward the rotation axis C. However, since the second base plate 262 can be offset with respect to the first base plate 261 by the above-mentioned linear guide 281 and fluid pressure cylinder 282, the position of the tip of the nozzle 23d of the spray gun 23 can be adjusted with respect to the rotation axis C. can be adjusted horizontally.

In this way, if the position of the tip of the nozzle 23d is set on the line of the rotation axis C shown in FIG. 4 to a position away from the rotation axis C as shown in FIG. The diameter D becomes smaller. Since the opening 16a of the intake port 16 has a larger diameter than the opening 17a of the exhaust port 17, when forming the valve seat film 16b on the opening 16a of the intake port 16, the rotation axis C shown in FIG. If the valve seat film 17b is formed at the opening 17a of the exhaust port 17, the valve seat film 17b may be located at a position away from the rotation axis C shown in FIG.

The working gas line 21b that guides the high pressure gas of 3 to 10 MPa supplied from the compressed gas cylinder 21a shown in FIG. It hangs down from the top of the base plate 26 attached to the hand 251 of the industrial robot 25 and reaches the spray gun 23 . In the vicinity of the base plate 26 between them, as shown in FIG. 4, they are separated and connected via a rotary joint 21k such as a swivel joint, and a heater 21i is provided below. The working gas line 21b from the rotary joint 21k to the chamber 23a shown in FIG. are being arranged. The working gas line 21b may be formed in advance into, for example, a spiral shape so as to surround the rotating shaft C. However, since a high pressure hose that can withstand high pressures of 3 to 10 MPa is hard and has shape retention properties, A shape retaining mold may be provided on the outer periphery so that the hose follows the spiral shape.

A raw material powder supply line 22c that guides the raw material powder supplied from the raw material powder supply device 22a shown in FIG. 3 to the spray gun 23 is arranged around the industrial robot 25 as a tube bundle 20 shown in FIG. It hangs down from the top and reaches the spray gun 23. Below the base plate 26 between them, the raw material powder supply line 22c is constituted by piping including a metal tube and a metal joint, and is connected to the chamber 23a of the spray gun 23, as shown in FIG.

Power supply lines 21j, 21j that lead the power supplied from the power source 21h shown in FIG. 3 to the heater 21i are arranged around the industrial robot 25 as a tube bundle 20 shown in FIG. , are connected to the heater 21i. Further, a signal line 23g that outputs a detection signal from the pressure gauge 23b shown in FIG. 3 to a controller (not shown) and a signal line 23h that outputs a detection signal from the thermometer 23c to a controller (not shown) The chamber 23a of the spray gun 23 is guided from the chamber 23a of the spray gun 23 to the second base plate 262 by passing through the pipe including a metal pipe and a metal joint, and is connected to the other working gas line 21b, the raw material powder supply line 22c, and the electric power. Together with the supply line 21j and the like, it is routed from the top of the base plate 26 to the periphery of the industrial robot 25.

An introduction pipe 274 and a discharge pipe 275 that guide the refrigerant supplied from the refrigerant circulation circuit 27 shown in FIG. 3 to the nozzle 23d of the spray gun 23 are arranged around the industrial robot 25 as a tube bundle 20 shown in FIG. It hangs down from the upper part of the base plate 26 and is connected to a refrigerant introduction part 23e at the tip of the nozzle 23d and a refrigerant discharge part 23f at the base end of the nozzle 23d. Below the base plate 26 between them, the introduction pipe 274 and the discharge pipe 275 are constructed of piping including a metal pipe and a metal joint, and are connected to the nozzle 23d of the spray gun 23, as shown in FIG.

As described above, the working gas line 21b, which is made up of a high-pressure hose that is hard and has high deformation rigidity, has its rotary joint 21k arranged on the axis of rotation C as shown in FIG. It is arranged along the rotation axis C so as to surround it. In addition, other than the working gas line 21b, the power supply lines 21j, 21j, the raw powder supply line 22c, the refrigerant introduction pipe 274 and the discharge pipe 275, and the signal lines 23g, 23h are connected to the rotation axis C, as shown in FIG. It is arranged at a position surrounding the working gas line 21b.

Next, a method for manufacturing the cylinder head 12 including the valve seat films 16b and 17b will be described. FIG. 9 is a process diagram showing the processing steps of the valve portion in the method of manufacturing the cylinder head 12 of this embodiment. As shown in the figure, the method for manufacturing the cylinder head 12 of this embodiment includes a casting process S1, a cutting process S2, a coating process S3, and a finishing process S4. Note that processing steps other than those for the valve portion will be omitted for the purpose of simplifying the explanation.

In the casting step S1, an aluminum alloy for casting is poured into a mold in which a sand core is set, and a cylinder head rough material having an intake port 16, an exhaust port 17, etc. formed in the main body is cast. The intake port 16 and the exhaust port 17 are formed by a sand core, and the recess 12b is formed by a mold. FIG. 10 is a perspective view of the cylinder head blank 3 cast in the casting process S1, viewed from the side of the mounting surface 12a to the cylinder block 11. The cylinder head blank 3 includes four recesses 12b, and two intake ports 16 and two exhaust ports 17 provided in each recess 12b. The two intake ports 16 and the two exhaust ports 17 of each recess 12b are gathered into one in the cylinder head blank 3 and communicate with openings provided on both sides of the cylinder head blank 3, respectively.

FIG. 11 is a sectional view of the cylinder head blank 3 taken along the line XI-XI in FIG. 10, and shows the intake port 16. The intake port 16 is provided with a circular opening 16a exposed within the recess 12b of the cylinder head blank 3.

In the next cutting step S2, the cylinder head rough material 3 is milled using an end mill, a ball end mill, or the like to form an annular valve seat portion 16c in the opening 16a of the intake port 16, as shown in FIG. The annular valve seat portion 16c is an annular groove serving as the base shape of the valve seat film 16b, and is formed on the outer periphery of the opening 16a. In the method for manufacturing the cylinder head 12 of this embodiment, a film is formed by spraying the raw material powder P onto the annular valve seat portion 16c by a cold spray method, and the valve seat film 16b is formed based on this film. Therefore, the annular valve seat portion 16c is formed to be one size larger than the valve seat membrane 16b.

In the coating step S3, the raw material powder P is injected onto the annular valve seat portion 16c of the cylinder head rough material 3 using the cold spray device 2 of this embodiment to form the valve seat film 16b. More specifically, in this covering step S3, after attaching the masking member 5 to the mounting surface 12a of the cylinder head blank 3, as shown in FIG. 23d in the same posture and at a constant distance, while fixing the cylinder head rough material 3, the spray gun 23 is rotated at a constant speed so that the raw material powder P is sprayed all around the annular valve seat part 16c. .

In the film forming method of this embodiment, a film is formed using a masking member 5, and the masking member 5 is used to form a film using a masking member 5. This prevents the adhesive from adhering to the mounting surface 12a of No. 3, etc. In particular, if the raw material powder P adheres to the surface of the mounting surface 12a of the cylinder head rough material 3 that contacts the cylinder block 11, the positioning accuracy in the subsequent manufacturing process may decrease, or the assembly accuracy of the finished engine product may deteriorate. or decrease. Further, if the raw material powder P adheres to the engine cooling water passage hole formed in the mounting surface 12a of the cylinder head rough material 3, the passage hole may be blocked or the hole diameter may become small. In this way, the masking member 5 shields the part where the raw material powder P adheres and causes a problem in the subsequent process.

The base material used for the masking member 5 is not particularly limited, but it is preferably a plate-shaped material that has enough strength to not be plastically deformed by cold spray injection of the raw material powder P, such as alumina, zirconia, nitride, etc. It is preferable to use a ceramic material containing at least one of titanium and silicon dioxide. By using these materials that are difficult to plastically deform, it is possible to suppress the adhesion of the raw material powder P, which is mainly a copper alloy type, and it becomes difficult for a film to be deposited on the masking member 5.

Further, the masking member 5 may be made of a metal having excellent chemical resistance, for example, a stainless steel material such as SUS304, and coated with nickel, iron, or the like, which can be peeled off by chemical treatment. Thereby, the surface of the masking member 5 on which the raw material powder P has been deposited can be easily peeled off by chemical treatment, and the masking member 5 can be easily recycled.

The tip of the nozzle 23d of the spray gun 23 is held by the hand 251 of the industrial robot 25 above the cylinder head 12 fixed to the base 45. As shown in FIG. 4, the base 45 or the industrial robot 25 is mounted on the cylinder head 12 or the sprayer so that the center axis Z of the intake port 16 on which the valve seat film 16b is formed is vertical and overlaps the rotation axis C. Set the position of gun 23. In this state, the spray gun 23 is rotated around the C axis by the motor 29 while spraying the raw material powder P from the nozzle 23d onto the annular valve seat portion 16c, thereby forming a film around the entire circumference of the annular valve seat portion 16c.

While this coating step S3 is being carried out, the nozzle 23d introduces the refrigerant supplied from the refrigerant circulation circuit 27 into the flow path from the refrigerant introducing portion 23e. The refrigerant cools the nozzle 23d while flowing from the front end to the rear end of a flow path formed inside the nozzle 23d. The refrigerant that has flowed to the rear end of the flow path is discharged from the flow path and recovered by the refrigerant discharge section 23f.

When the spray gun 23 completes one rotation around the C-axis and the formation of the valve seat film 16b is completed, the rotation of the spray gun 23 is temporarily stopped. While the rotation is stopped, the industrial robot 25 moves the spray gun 23 so that the central axis Z of the intake port 16, on which the valve seat membrane 16b is next formed, coincides with the reference axis of the industrial robot 25. After the industrial robot 25 finishes moving the spray gun 23, the motor 29 restarts the rotation of the spray gun 23 to form the valve seat film 16b at the next intake port 16. Thereafter, by repeating this operation, valve seat films 16b and 17b are formed on all the intake ports 16 and exhaust ports 17 of the cylinder head blank 3. Note that when the formation target of the valve seat film is switched between the intake port 16 and the exhaust port 17, the inclination of the cylinder head rough material 3 is changed by the base 45. Once the coating has been formed on all the annular valve seat portions 16c, the masking member 5 is removed from the mounting surface 12a of the cylinder head blank 3.

Now, FIG. 16 shows an example of the movement trajectory MT when the nozzle 23d of the cold spray device 2 moves through each opening of the intake port 16 and the exhaust port 17 in the film forming method according to the present invention. FIG. 3 is a plan view of No. 3. The nozzle 23d is moved relative to the openings 16a of the eight intake ports 16 and the openings 17a of the eight exhaust ports 17 of the cylinder head blank 3 shown in FIG. 16 along the movement trajectory MT shown by the arrow. Note that although the movement trajectory MT for the intake port 16 will be described below, the movement trajectory for the exhaust port 17 is also set in the same way.

As described above, when the nozzle 23d rotates 360 degrees clockwise with respect to one intake port 16, it rotates 360 degrees counterclockwise with respect to the next intake port 16. Then, the nozzle 23d moves repeatedly clockwise and counterclockwise with respect to the eight intake ports 16. That is, the nozzle 23d rotates counterclockwise to the four intake port openings 16a8, 16a6, 16a4, and 16a2 shown in FIG. 16, and rotates counterclockwise to the remaining four intake port openings 16a7, 16a5, and 16a3. , 16a1, it rotates clockwise.

Here, the movement locus MT for the eight intake ports 16 is composed of a circular locus T for each of the annular valve seat portions 16c of each intake port 16, and a connection locus CT connecting adjacent circular loci T. , is considered to be a series of continuous trajectories. Then, the nozzle 23d is moved along the movement trajectory MT while continuously injecting the raw material powder from the nozzle 23d without interruption. Note that the circular trajectory T for one annular valve seat portion 16c starts from the film-forming start point, moves clockwise or counterclockwise, wraps at the film-forming start point, and makes this lap part the film-forming end point. . Note that illustration of the masking member 5 is omitted in FIG. 16.

FIG. 17 is an enlarged plan view showing the movement locus MT for the openings 16a8 and 16a7 of one intake port 16 located at the lower right of FIG. 16. The masking member 5 is held by a robot or the like, for example, and is attached to the mounting surface 12a of the cylinder head blank 3 so as to cover the outer periphery of the recess 12b of the cylinder head blank 3 where the film is to be formed. The illustrated masking member 5 is composed of a plate in which an opening corresponding to the diameter of a cylinder including two intake ports and two exhaust ports is formed. (A), (B), and (C) shown in FIG. 17 are movement trajectories corresponding to each cylinder head raw material 3 when film formation is applied to each different cylinder head raw material 3 that is manufactured continuously. Indicates MT. Note that the following movement trajectory MT is taught in advance to the control device of the industrial robot 25 to which the spray gun 23 is attached.

In the first cylinder head blank 3, as shown in FIG. 17(A), the movement trajectory MT of the opening 16a8 of the intake port 16 relative to the annular valve seat portion 16c is from the right end to the left in the figure. The nozzle 23d is moved linearly to the lower left of the annular valve seat portion 16c, and this is set as the turning point TP1a of the first layer. Then, the direction is changed at the turning point TP1a, and the nozzle 23d is moved diagonally upward and to the right toward the annular valve seat portion 16c, and then the nozzle 23d is rotated counterclockwise along a circular trajectory T with this as the starting point for film formation. Then, the film formation end point that overlaps with the film formation start point is set as the turning point TP2a of the second layer, and the direction is changed, and the nozzle 23d is moved in the direction of the opening 16a7. At this time, the turning point TP1a is set to be above the connection locus CT1 and above the masking member 5.

On the other hand, in the second cylinder head raw material 3, as shown in FIG. 17(B), the movement trajectory MT of the opening 16a8 of the intake port 16 with respect to the annular valve seat portion 16c crosses the turning point TP1b of the first layer. It is to be set on the masking member 5 on the connection locus CT1 and on the left side of the position (TP1a) set in FIG. On the other hand, in the third cylinder head blank 3, as shown in FIG. 17(C), the movement locus MT of the opening 16a8 of the intake port 16 with respect to the annular valve seat portion 16c crosses the turning point TP1c of the first layer. It is set above the connection locus CT1 and further to the left of the positions (TP1a, TP1b) set in FIGS. At this time, the turning points TP2b and TP2c of the second layer in FIGS. 17(B) and 17(C) may be at the same position as the turning point TP2a set in FIG. 17(A). Note that the turning points TP1a, TP1b, TP1c, TP2a, TP2b, and TP2c refer to points on the movement trajectory MT where the movement speed of the nozzle 23d decreases to zero or a value close to zero, and the movement trajectory is at a right angle or an acute angle (≦ 90°). As a result, when forming a film on a plurality of cylinder head raw materials 3, the folding points TP1a, TP1b, and TP1c are dispersed and set at different positions on the masking member 5, and the raw material powder P is applied to the masking member 5. can be prevented from being deposited in specific locations.

In the present embodiment shown in FIG. 17, the turning points TP1a, TP1b, and TP1c are set at different positions along the left direction in the figure, but since it is sufficient to avoid overlapping, TP1a, TP1b, TP1c may be set at different positions along the right direction, or may be set at different positions alternately in the left direction and right direction.

FIG. 18 is a plan view showing another example of the movement trajectory MT for the openings 16a8, 16a7 of one intake port 16 located at the lower right of FIG. 16. (A), (B), and (C) shown in FIG. 18 illustrate each cylinder head rough material when film formation is applied to each different cylinder head rough material 3 that is manufactured continuously, as in FIG. 17. 3 shows a movement trajectory MT corresponding to No. 3.

In the first cylinder head blank 3, as shown in FIG. 18(A), the movement trajectory MT of the opening 16a8 of the intake port 16 with respect to the annular valve seat portion 16c is from the right end to the left in the figure. The nozzle 23d is moved linearly to the lower left of the annular valve seat portion 16c, and this is set as the turning point TP1a of the first layer. Then, the direction is changed at the turning point TP1a, and the nozzle 23d is moved diagonally upward and to the right toward the annular valve seat portion 16c, and then the nozzle 23d is rotated counterclockwise along a circular trajectory T with this as the starting point for film formation. let At this time, the nozzle 23d is moved linearly to the lower right of the annular valve seat portion 16c after passing through the film formation end point that overlaps with the film formation start point, and this is set as the turning point TP2a of the second layer. Then, the direction is changed at the turning point TP2a, and the nozzle 23d is moved toward the opening 16a7.

In this way, in the movement trajectory MT according to the embodiment shown in FIG. 18, the turning point TP1a of the first layer is set on the connection trajectory CT1, and the turning point TP2a of the second layer is also set on the connection trajectory CT2. The folding points TP1a and TP2a are both set on the masking member 5.

Next, in the second cylinder head raw material 3, as shown in FIG. 18(B), the movement trajectory MT of the opening 16a8 of the intake port 16 with respect to the annular valve seat portion 16c is the turning point TP1b of the first layer. is set on the connection locus CT1 and on the masking member 5 to the left of the position (TP1a) set in FIG. Furthermore, the turning point TP2b of the second layer is set on the connection locus CT2 and on the masking member to the right of the position (TP2a) set in the same figure (A). . By the same method, in the movement trajectory MT for the third cylinder head rough material 3, shown in FIG. (TP1a, TP1b) is set on the masking member 5 further to the left, and the turning point TP2c of the second layer is set at the position (TP2a, TP2b) set in (A) and (B) of the same figure. It is set on the masking member 5 further to the right.

FIG. 19 is a cross-sectional view showing the discharge angle of the nozzle 23d with respect to the masking member 5 in the film forming method according to the present invention, and FIG. 20 is an enlarged view showing the section XX in FIG. 19(B). The masking member 5 of the present invention may be used as it is with a uniform or uniform thickness as shown in FIG. 19(A), but if necessary, as shown in FIG. 19(B) and FIG. It may also be used by forming recesses 51 on the surface. The recesses 51 provided on the surface of the masking member 5 are formed in a range corresponding to the turning points TP1a, TP1b, TP1c of the first layer in the connection trajectory CT1 and the turning points TP2a, TP2b, TP2c of the second layer in the connection trajectory CT2. . At these turning points, the moving speed of the nozzle 23d decreases to zero or a value close to zero, so the injection of the raw material powder P is concentrated and the film is deposited the most. By forming the recesses 51 in advance in locations where the film is likely to accumulate, as shown in FIG. 20, it is possible to smooth out the upheaval on the surface of the masking member 5 due to the accumulation of the raw material powder P.

In addition, when the masking member 5 is used with a recess 51 formed on the surface, the discharge angle θ2 of the nozzle 23d with respect to the masking member 5 is set so that the recess 51 is formed on the surface of the masking member 5, as shown in FIG. 19(B). The discharge angle is smaller than the discharge angle θ1 (≦90°) in the case where no discharge angle is used. FIG. 22 is a graph showing the relationship between the particle velocity V ₀ of the raw material powder P and the inclination (discharge angle θ) of the nozzle 23 d with respect to the discharge surface on the discharge surface where the raw material powder P is discharged. As shown in FIG. 22, the velocity component perpendicular to the discharge surface is proportional to the deposition rate of the raw material powder P. That is, when the discharge angle θ of the nozzle 23d is θ=90°, the vertical velocity component has the largest value, and the deposition rate of the raw material powder P becomes the highest. On the other hand, if the discharge angle θ of the nozzle 23d is 0≦θ<90° or 90<θ≦180°, the velocity component perpendicular to the discharge surface is V ₀ Sin θ, so the discharge angle θ is smaller than 90°. As the velocity component decreases, the deposition rate of the raw material powder P decreases. Thereby, the adhesion rate of the raw material powder P adhering to the surface of the masking member 5 can be lowered, and as a result, it is possible to suppress the raw material powder P from being thickly deposited on a specific location of the masking member 5.

21(A) is a sectional view showing the discharge angle with respect to the nozzle 23d and the annular valve seat portion 16c in the film forming method according to the present invention, and FIG. 21(B) is a sectional view showing the discharge angle with respect to the nozzle 23d and the masking member 5. FIG. In this embodiment, when the nozzle 23d moves on the movement path MT, the raw material powder P is discharged at an ejection angle with respect to the discharge surface on which the raw material powder P is discharged, that is, the raw material powder P is discharged with respect to the masking member 5 at a discharge angle θ4 (FIG. 21 (B)) is made smaller than the discharge angle θ3 (see FIG. 21(A)) with respect to the annular valve seat portion 16c which is the film-forming portion, thereby reducing the thickness of the film deposited on the masking member 5. It is.

As shown in FIG. 21(B), the discharge angle θ4 of the raw material powder P with respect to the masking member 5 is made smaller than the discharge angle θ3, for example, as close to parallel to the masking member 5 as possible. As a result, the width W2 of the coating formed on the masking member 5 at the discharge angle θ4 is wider than the width W1 of the coating formed on the annular valve seat portion 16c at the discharge angle θ3, but the width W2 of the coating formed at the discharge angle θ4 is The thickness of the film can be made thinner than the thickness of the film formed at the discharge angle θ3. As a result, it is possible to further suppress the raw material powder P from accumulating on the masking member 5.

Returning to FIG. 9, in the finishing step S4, the valve seat films 16b, 17b, the intake port 16, and the exhaust port 17 are finished. In finishing the valve seat films 16b and 17b, the surfaces of the valve seat films 16b and 17b are cut by milling using a ball end mill, and the valve seat films 16b are shaped into a predetermined shape. In addition, in finishing the intake port 16, a ball end mill is inserted into the intake port 16 from the opening 16a, and the inner circumferential surface of the intake port 16 on the opening 16a side is cut along the processing line PL shown in FIG. . The processing line PL is a region in which a relatively thick surplus film SF is formed by scattering and adhering the raw material powder P into the intake port 16, and more specifically, a region where the surplus film SF has an effect on the intake performance of the intake port 16. This is the range where the thickness is formed to a certain degree.

In this manner, the finishing step S4 eliminates surface roughness of the intake port 16 due to casting, and also removes the excess film SF formed in the coating step S3. FIG. 15 shows the intake port 16 after the finishing step S4. The exhaust port 17, like the intake port 16, is formed by forming a small diameter part inside the exhaust port 17 by casting, forming an annular valve seat part by cutting, cold spraying the annular valve seat part, and finishing. After that, the valve seat film 17b is formed. Therefore, a detailed explanation of the procedure for forming the valve seat film 17b for the exhaust port 17 will be omitted.

As described above, according to the film-forming method of this embodiment, when film-forming is performed on a plurality of cylinder head blanks 3, the masking member 5 set for the current cylinder head blank 3 is Since the turning point TP1b is set at a different position from the position TP1a set for the previous cylinder head rough material 3, it is possible to suppress the raw material powder P from being deposited at a specific location on the masking member 5. Can be done.

Further, according to the film forming method of the present embodiment, the masking member 5 is made of a ceramic material containing at least one of alumina, zirconia, titanium nitride, and silicon dioxide, so that it mainly suppresses the adhesion of the copper alloy-based raw material powder P. This makes it difficult for a film to accumulate on the masking member 5.

Further, according to the film forming method of the present embodiment, since the masking member 5 has the recesses 51 formed in the range corresponding to the folding points TP1a, TP1b, and TP1c, the surface of the masking member 5 due to the deposition of the raw material powder P It can smooth out the bumps.

Further, according to the film forming method of the present embodiment, the masking member 5 has the concave portions 51 formed in the range corresponding to the turning points TP1a, TP1b, and TP1c, and the discharge angle of the nozzle 23d with respect to the masking member 5 is smaller than 90°. Therefore, the adhesion rate of the raw material powder P can be lowered, and as a result, it is possible to suppress the raw material powder P from being thickly deposited on a specific location of the masking member 5.

Furthermore, according to the film forming method of the present embodiment, the discharge angle θ4 of the raw material powder P with respect to the masking member 5 is smaller than the discharge angle θ3 with respect to the annular valve seat portion 16c, which is the part to be deposited. The thickness of the coating becomes thinner, and the deposition of the raw material powder P on the masking member 5 can be further suppressed.

1... Internal combustion engine 11... Cylinder block 11a... Cylinder 12... Cylinder head 12a... Mounting surface 12b... Recessed part 12c, 12d... Side surface 13... Piston 13a... Connecting rod 13b... Top surface 14... Crankshaft 15... Combustion chamber 16... Intake port 16a...Opening part 16b...Valve seat membrane 16c...Annular valve seat part 17...Exhaust port 17a...Opening part 17b...Valve seat membrane 18...Intake valve 18a...Valve stem 18b...Valve head 18c...Valve guide 19...Exhaust valve 19a... Valve stem 19b...Valve head 19c...Valve guide 2...Cold spray device 21...Gas supply section 21a...Compressed gas cylinder 21b...Working gas line 21c...Carrying gas line 21d...Pressure regulator 21e...Flow rate control valve 21f...Flow meter 21g... Pressure gauge 21h...Power source 21i...Heater 21j...Power supply line 21k...Rotary joint 22...Raw material powder supply unit 22a...Raw material powder supply device 22b...Measuring instrument 22c...Raw material powder supply line 23...Spray gun 23a...Chamber 23b...Pressure Total 23c... Thermometer 23d... Nozzle 23e... Refrigerant introduction part 23f... Refrigerant discharge part 23g... Signal line 24... Base material 24a... Film 25... Industrial robot 251... Hand 252... Bracket 26... Base plate 261... First base plate 262... Second base plate 263...Cover 27...Refrigerant circulation circuit 271...Tank 272...Pump 273...Cooler 274...Introduction pipe 275...Discharge pipe 28...Offset mechanism 281...Linear guide 282...Fluid pressure cylinder 29...Motor 291...Drive shaft 3 ...Cylinder head rough material 4...Film forming factory 41...Transport booth 42...Film forming booth 43, 44...Door 45...Base 5...Masking member 51...Concavity MT...Trajectory of movement T...Trajectory of film forming part CT1, CT2 …Connection trajectory TP1, TP2…turning point

Claims (4)

After attaching a masking member to the workpiece that covers part or all of a workpiece having a plurality of discontinuous film-forming parts other than the film-forming parts, the workpiece and the nozzle of the cold spray device are connected to the plurality of film-forming parts. While continuously injecting the raw material powder from the nozzle, the raw material powder is move it to
A turning point at which the relative speed between the workpiece and the nozzle becomes low in the movement trajectory is set on the connection trajectory and on the masking member,
In a film forming method in which a film is formed by spraying raw material powder onto each of the plurality of film forming parts by a cold spray method,
When performing film deposition processing on multiple workpieces, a film deposition method in which the folding point on the masking member set for the current workpiece is set at a position different from the position set for the previous workpiece. . 2. The film forming method according to claim 1, wherein the masking member is made of a ceramic material containing at least one of alumina, zirconia, titanium nitride, and silicon dioxide. 3. The film forming method according to claim 1, wherein the masking member has a recess formed in a predetermined range of the surface corresponding to the folding point. 4. The film forming method according to claim 1, wherein at the turning point, a discharge angle of the raw material powder by the nozzle is smaller than a discharge angle of the raw material powder with respect to the film-forming target portion.

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