JPH1018903A - Manufacture of cylinder block - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a method for manufacturing a cylinder block excellent in mechanical strength and a vibration damping property. SOLUTION: In a cylinder block 1 equipped with a cylinder block main body 3 made of an aluminum alloy, and a joining member 5 to be joined to the cylinder block main body 3, the joining member 5 is constituted of a damping alloy, and also material, having a damping coefficient range of 10-100 times that of the aluminum alloy of the cylinder block main body 3, is used as the damping alloy, and ultrasonic vibration is applied to at least one side of the cylinder block main body 3 and the joining member 5, to form a zinc alloy soldering layer on a surface, and then the joining member 5 is joined to a strong-vibration region at the time of operation in the cylinder block main body 3.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

The present invention relates to a method of manufacturing a cylinder block, and more particularly to a method of manufacturing a cylinder block used for an automobile engine.

[0002]

2. Description of the Related Art A cylinder block of a water-cooled internal combustion engine such as an engine for an automobile has recently been particularly made of aluminum. Here, as the type of the cylinder block, there are a so-called closed deck type and an open deck type.

Here, in the open deck type, a cooling water passage is formed around the entire periphery of a cylinder, and the entire periphery of the cooling water passage on the upper end face of the cylinder block is opened, so that the cooling water passage is made up of glasses. It is formed in a shape. This open deck type is usually manufactured by a die casting method. Here, in the open deck type, since the entire upper end of the cylinder block is released, the strength of this region is low, and vibration and noise due to combustion in the cylinder during operation are likely to occur. For this reason,
Conventionally, the following improvements have been proposed.

That is, for the purpose of improving the strength of a cylinder block, for example, Japanese Patent Laid-Open Publication No.
In Japanese Patent Laid-Open Publication No. H11 (first conventional example), a proposal is made to fix a piece member having a predetermined shape by welding to an opening of a cooling water passage. Also, Japanese Patent Application Laid-Open No. 1-147145 (No. 2)
In the conventional example, a predetermined piece member is welded and fixed to the opening of the cooling water passage as in the first conventional example. In particular, the piece member is made of an aluminum alloy having a higher melting point than the cylinder block body. It is. In addition, Japanese Patent Laid-Open No. 2-1
In Japanese Patent Application Publication No. 05557 (third conventional example), a predetermined plug member (piece member) is made of a material having a lower melting point than the cylinder block main body, and this is heated by a heat source such as an arc or a laser to the cylinder block main body. Weld.

[0005] As means for suppressing vibration and noise generated from the engine, the following has been proposed. That is, when the engine is fixed to the engine mount of the vehicle body, the engine is installed via a damper member mainly composed of an elastic material such as rubber. Thereby, vibrations and sounds generated from the engine are not transmitted to the vehicle body.

[0006]

However, the above-mentioned prior art has the following disadvantages. That is, when an open deck cylinder block body is manufactured by die casting, gas is dispersed and trapped as fine voids in the casting due to the characteristics of this manufacturing method. For this reason, the conventional welding method (laser, arc welding, etc.) has a disadvantage that gas defects appear remarkably and sufficient mechanical joining strength cannot be obtained.

Further, the third conventional example in which a metal material having a lower melting point than the material of the cylinder block is melted by the heat of the heat source has the following disadvantages. That is, a strong oxide film is formed on the aluminum surface of the cylinder block after casting, and cannot be firmly welded by an existing welding method or the like. On the other hand, even when welding is performed after surface treatment using a flux or the like, it is difficult to ensure sufficient bonding strength. Conversely, there has been a disadvantage that the flux induces corrosion of the aluminum member and the like.

Further, when a cylinder block is manufactured by joining a piece member or the like to the cylinder block main body as described above, it is partially effective for the purpose of increasing the strength of the cylinder block itself. Therefore, it is not possible to suppress the generation of vibration and noise from the engine. For this reason, it is necessary to use a conventionally used damper member and the like separately from the engine, and these members occupy a part of the space of the engine room. In addition, when the engine is installed via a damper member or the like, there has been a problem that the mounting operation is complicated.

[0009]

SUMMARY OF THE INVENTION It is an object of the present invention to provide a method for manufacturing a cylinder block which is improved in the disadvantages of the prior art and has particularly excellent mechanical strength and vibration damping properties.

[0010]

According to one aspect of the present invention, there is provided a cylinder having a cylinder block body made of an aluminum alloy and a joining member joined to the cylinder block body. In the block,
The joining member is made of a damping alloy, and a damping coefficient of the damping alloy is in a range of 10 to 100 times that of the aluminum alloy of the cylinder block body. At least one of the cylinder block body and the joining member is used. Ultrasonic vibration is applied to form a zinc alloy solder layer on the surface, and then the joining member is joined to a large vibration region in the cylinder block body during operation.

The operation of the above-described method for manufacturing a cylinder block will be described. The cylinder block body is formed of an aluminum alloy casting, and the joining members are individually formed of a damping alloy such as Zn-Al. Then, a zinc alloy solder layer is formed on the joining portion of the cylinder block body and the surface of the joining member by applying ultrasonic vibration. afterwards,
The joining member is inserted into the joining portion (the passage wall surface of the cooling water passage) via the zinc alloy solder layer while preheating. That is, it is inserted between the passage wall surfaces of the opened cooling water passage at the upper end of the cylinder block body. Then, the joining member is further inserted into the passage wall surface with a predetermined pressing force.

At the same time, the joining member or the cylinder block body is heated and ultrasonic vibration is applied to melt the zinc alloy solder layer. As a result, a zinc alloy solder layer is generated at the joint between the cylinder block body and the joining member,
By stopping the heating and the ultrasonic vibration, the temperature of the joint is reduced, and the two are joined firmly.

According to the second aspect of the present invention, the internal wear value (Q ^-1 × 1) of the vibration damping alloy in a range from room temperature to 150 ° C.
0 ³ ) is 0.2 or more, and the other configuration is the same as that of the first aspect.

Next, a third aspect of the present invention employs a configuration in which a Zn-based damping alloy is used as the damping alloy, and the other configurations are the same as those of the first or second aspect.
With the above configuration, when joining the cylinder block body and the joining member, the wettability with the molten zinc alloy solder is good, the ultrasonic soldering is easy, and high joining strength can be obtained. .

Further, the invention according to claim 4 employs a structure in which an Al-based vibration damping alloy is used as the vibration damping alloy, and the other structure is the same as that of the invention according to claim 1 or 2.

[0016]

DESCRIPTION OF THE PREFERRED EMBODIMENTS Hereinafter, an embodiment of the present invention will be described.
This will be described with reference to the drawings.

FIG. 1 is a perspective view showing a cylinder block 1 according to the present invention. The cylinder block 1 includes a cylinder block body 3 made of an aluminum alloy, and a joining member 5 joined to the cylinder block body 3. The joining member 5 is made of a vibration damping alloy. Is used whose damping coefficient is in the range of 10 to 100 times the aluminum alloy of the cylinder block body 3. Then, ultrasonic vibration is applied to at least one of the cylinder block main body 3 and the joining member 5, and a zinc alloy solder layer is formed on the surface. Thereafter, the joining member 5 is joined to the large vibration region of the cylinder block body 3 during operation.

In this case, when the joining member 5 is joined to the cylinder block body 3, the periphery of both joining portions 7 is uniformly heated, and the ultrasonic wave is applied while the joining member 5 is pressed against the cylinder block body 3. The process of applying vibration and joining is adopted. When heating the periphery of the joint 7, a high-frequency heating method is used to uniformly heat the periphery. However, the heating method is not limited to this. For example, low-frequency heating may be used, or an LPG gas burner or the like may be used. Heating. Also, while the joining member 5 is inserted into the cylinder block main body 3, it is put into a heating furnace (not shown), the whole is heated, then taken out of the heating furnace, and ultrasonic vibration is applied while applying a predetermined pressure as described above. You may make it join.

More specifically, as shown in FIG. 2, the cylinder block body 3 according to the present embodiment is a die-cast product made of an aluminum alloy. The materials are ADC10 and ADC12 which are generally used.
And ADC14. Also, the cylinder liner 11
A cooling water passage 9 is formed in the entire periphery of the cooling water passage.

The upper end of the cooling water passage 9 is opened before the joining member 5 is inserted. Here, the upper end of the cylinder block body 3 is flattened so that a cylinder head (not shown) is mounted. The cooling water passage 9 is shaped like a pair of glasses so as to surround the periphery of each cylinder (FIG. 1).
), And the cooling water passages 9 of all the cylinders are interconnected.

A crankcase 13 is formed in a lower region of the cylinder block body 3 so that a predetermined crankshaft (not shown) is mounted inside. The lower end of the crankcase 13 is formed as a flat surface so as to contact a bottom case (not shown), and is connected to each other by a bolt member (not shown).

Next, a specific method of manufacturing the cylinder block 1 will be described. First, an open deck type cylinder block body 3 in which the entire upper end of the cooling water passage 9 is opened is used. The cylinder block body 3 is manufactured by a die casting method and then preheated to a maximum of about 350 ° C. through predetermined machining.

Then, as shown in FIG. 6, a part (the area near the joint 7) is immersed in a molten zinc alloy solder bath 15 to form a zinc alloy solder layer on the joint 7 of the cooling water passage 9. Is done. Specifically, a zinc alloy solder layer is formed up to about 30 [mm] from the upper end surface on the side where the cylinder head (not shown) is mounted. In this case, for example, AH-Z95A (JIS Z3281) having a melting point of about 382 [° C.] is used as the zinc alloy solder. This zinc alloy solder is melted to 410 [° C] to 4
The above-described joint 7 is immersed in a zinc alloy solder bath 15 maintained at 30 ° C., and ultrasonic vibration is applied.

Here, an apparatus for applying ultrasonic vibration to the cylinder block main body 3 will be described in detail. As shown in FIG.
7 and the above-mentioned upper end portion is a zinc alloy solder bath 1
5 dipped. What holds the zinc alloy solder bath 15 is a solder bath 19 with a heater, which maintains the temperature of the molten solder at the above-mentioned predetermined value. Further, an ultrasonic oscillator 21 is engaged with the diaphragm 17 so that ultrasonic vibration is transmitted. The ultrasonic oscillating device 21 includes a horn 2 for applying vibration to the diaphragm 17.
3, a vibrator 25 for transmitting vibration to the horn 23, and an oscillator 27 for transmitting an oscillation signal to the vibrator 25.

Here, in FIG. 6, the upper and lower parts of the diaphragm 17 are described as being divided, but the diaphragm 17 is immersed in the zinc alloy solder bath 15 to a predetermined depth. Indicates a certain state.

On the other hand, when manufacturing the joining member 5, first, the joining member 5 is formed in a shape and a size that can be inserted into the passage wall surface of the cooling water passage 9. At this time, the joining member 5 is made of the damping alloy as described above. This vibration-damping alloy (also called "vibration-proof alloy") has a very high internal friction, and can rapidly attenuate even if vibration is applied to a member made of this alloy. .

Here, the internal friction will be briefly described. When a metal crystal is vibrated in various ways, the amplitude gradually decreases and the vibration energy is absorbed. this is,
Considering that the metal crystal has resistance to elastic deformation that can be compared to friction, this is called internal friction.

The damping alloy used for the joining member 5 has a damping coefficient of about 10 to 100 times that of the material (aluminum alloy) of the cylinder block body 3. Here, the damping coefficient refers to a ratio at which elastic energy is lost in each cycle when a shear stress of 1/10 of the 0.2% proof stress is applied. Other conditions for the damping alloy include an internal wear value from normal temperature to 150 ° C. (Q ⁻¹ × 10 ³ )
Is 0.2 or more. Here, the internal wear value will be briefly described. Q is a value representing the sharpness of resonance, and the resonance frequency of a predetermined member is a half-value width (the width of the frequency including the amplitude when the maximum amplitude is divided by the square root of 2). ). And the reciprocal Q of this Q
^-1 is the energy decay rate when vibration is absorbed = 2πQ
There is a relationship of ^-1 . Therefore, the larger the value of Q- ¹ , the better the vibration damping property.

The composition of the damping alloy used in the present embodiment will be described. As a Zn-based damping alloy, for example, when each component is expressed by weight%, Al is 20% to 40%.
%, Si, Cu, Mn, Mg, etc. are combined in trace amounts, and the remaining 50% is Zn. As the Al-based vibration damping alloy, Zn is about 40%, Si is about 6%,
In addition to about 1% of Cu, a small amount of Mn, Mg and the like are combined in small amounts, and the remaining about 60% is made of Al. An overview of the physical properties of the vibration damping alloy thus configured is as follows.
For example, the above-mentioned Zn-based damping alloy has a density of 4.1.
G / cm ³ ] and an electric conductivity of 27.4 [% IAC]
S], melting point 516 [° C.], specific heat 590 [J / Kg /
° C] and the coefficient of linear expansion is 25.6 [10 ^ー / ° C].

The joining member 5 made of a material satisfying the above conditions is preheated as in the case of the cylinder block body 3, and is immersed in a zinc alloy solder bath and subjected to ultrasonic vibration. At this time, the conditions for forming the zinc alloy solder layer are almost the same as those for the cylinder block body 3 described above. As described above, a zinc alloy solder layer is formed on the surface of the joining member 5. Here, when the joining member 5 is immersed in a zinc alloy solder bath, a zinc alloy solder layer is formed on the entire joining member 5, but this does not pose any problem in manufacturing.

Next, a process of inserting the joining member 5 into the cylinder block body 3 and joining will be described. As described above, the cylinder block main body 3 and the joining member 5 each having the zinc alloy solder layer formed thereon are prepared. As shown in FIG. 2, the joining member 5 is located at the upper end of the cylinder block main body 3 and in the cooling water passage 9. Inserted. The upper end of the cylinder block main body 3 is one of the weakest parts of the open deck type cylinder block main body 3, and is a so-called large vibration area.

Subsequently, the cylinder block body 3 in which the joining member 5 is inserted into the cooling water passage 9 is installed in a separately provided ultrasonic joining device (not shown). The ultrasonic bonding apparatus has an air cylinder that carries the cylinder block main body 3 and abuts the cylinder block main body 3 on a horn bonded to an ultrasonic vibrator described later. Further, a predetermined ultrasonic oscillator is provided above the air cylinder. The ultrasonic oscillator includes a horn that directly vibrates the joining member 5, a vibrator that transmits vibration to the horn, and an oscillator that applies an oscillation signal to the vibrator.

A predetermined heating device is provided near the horn. This heating device is for preheating the joint between the cylinder block main body 3 and the joining member 5, and is constituted by a high-frequency heater. However, the heating device is not limited to this, and may be, for example, a gas burner using LPG gas.

Then, the cylinder block body 3 carried on the air cylinder is moved upward by the action of the air cylinder, and abuts on the horn disposed above it. Rather, the joining member 5 inserted into the passage wall surface and still projecting comes into contact with the horn. afterwards,
The joint 7 is heated by the above-described heating device and is subjected to ultrasonic vibration. At this time, the air cylinder
Since the cylinder block body is constantly pressed against the horn with a predetermined pressure, the zinc alloy solder layer is melted with the application of heating and ultrasonic vibration, and the joining member 5 is inserted into the cylinder block body 3.

Through the above steps, the cylinder block main body 3 and the joining member 5 are integrated, and finally, a predetermined machining is applied to the cylinder block 1 shown in FIG. 1 or FIG.
Is completed.

For reference, FIGS. 3 and 4 show an application example of the present invention to another cylinder block main body of the open deck type. These cylinder block bodies 3a, 3b
Are called a half wet liner type and a wet liner type, respectively. After casting the cylinder block main body, separate cylinder liners 11 whose outer peripheral surfaces are processed are press-fitted into the cylinder block main bodies 3a and 3b. Therefore, as can be seen from the drawings, in this case, the joining member 5 made of the above-described damping alloy and the cylinder sleeve 11 made of cast iron are joined in different kinds. However, by properly selecting the material of the joining member 5 and the material of the solder, strong joining is possible.

Although the case where ultrasonic vibration is applied at the time of joining the cylinder block body 3 and the joining member 5 has been described above, the present invention is not limited to this. The same effect can be obtained only by heating and pressurizing the vicinity of the portion 7 to a temperature higher than the melting point of the zinc alloy solder.

In the above-described embodiment, the case where the joining member 5 is inserted into the cooling water passage 9 of the cylinder block main body 3 and joined is described. However, the present invention is not limited to this. For example, as shown in FIG. 5, a sealing member 5a that covers the entire upper end surface of the cylinder block body 3c is used as a joining member, and the lower surface of the sealing member 5a and the upper end surface of the cylinder block body 3c are joined to each other. It may be. By joining the sealing member 5a to the entire periphery of the cylinder liner 11 in this manner, the mechanical strength of the cylinder block 1c is dramatically improved. At the same time, the upper end of the open deck cylinder block, which has the least strength, is joined by the sealing member 5a made of a vibration damping alloy, so that vibration of this portion is appropriately suppressed, and unpleasant noise is also generated. Is reliably suppressed.

[0039]

As described above, according to the present invention, the joining member is ultrasonically soldered to the open deck type cylinder block main body, so that the cylinder block main body can be manufactured at a low cost by die casting or the like. It is possible to manufacture a cylinder block having the same strength as a closed deck type having excellent mechanical strength because the wall surface of the cooling water passage is joined by a joining member by ultrasonic soldering. Is generated. In addition, since the die casting method can be used, productivity can be improved.

Further, since the joining member is made of a vibration damping alloy, in addition to the above-described effect of improving the mechanical strength, vibration and noise caused by combustion of the engine and transmitted to the vicinity of the joining member are efficiently suppressed. , Which is an excellent effect. Further, as a result of suppressing the vibration, there is an excellent effect that the damper member conventionally used for mounting the engine becomes unnecessary, and the manufacturing cost can be reduced.

Further, a Zn-based or Al
Since the base material is used, the wettability (affinity) with the zinc alloy solder used for bonding is good, so that an excellent effect that ultrasonic soldering is easy and high bonding strength can be obtained is produced. .

[Brief description of the drawings]

FIG. 1 is a perspective view showing a cylinder block according to an embodiment of the present invention.

FIG. 2 is a side sectional view of the cylinder block disclosed in FIG. 1;

FIG. 3 is a sectional view showing a case where the present invention is applied to a half wet liner type cylinder block main body.

FIG. 4 is a sectional view showing a case where the present invention is applied to a wet liner type cylinder block main body.

FIG. 5 is a view showing a modification of the present invention, and is a cross-sectional view showing a case where a sealing member is joined to the entire upper surface of the cylinder block main body.

FIG. 6 is a sectional view showing an apparatus for forming a zinc alloy solder layer on a cylinder block main body.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Cylinder block 3 Cylinder block main body 5 Joining member 7 Joining part 9 Cooling water passage 11 Cylinder liner

Claims (4)

[Claims] 1. A cylinder block comprising a cylinder block body made of an aluminum alloy and a joining member joined to the cylinder block body, wherein the joining member is made of a damping alloy, and the damping alloy has Use a cylinder whose damping coefficient is in the range of 10 to 100 times the aluminum alloy of the cylinder block main body, and apply a ultrasonic vibration to at least one of the cylinder block main body and the joining member to form a zinc alloy solder layer on the surface. Thereafter, the joining member is joined to a large vibration region during operation of the cylinder block body during the operation of the cylinder block body. 2. The cylinder according to claim 1, wherein the damping alloy has an inner wear value (Q ^-1 × 10 ³ ) of 0.2 or more in a range from room temperature to 150 ° C. Block manufacturing method. 3. The method according to claim 1, wherein the damping alloy is a Zn-based damping alloy. 4. The method for manufacturing a cylinder block according to claim 1, wherein the damping alloy is an Al-based damping alloy.