US20050263219A1 - Device and method for remelting metallic surfaces - Google Patents

Device and method for remelting metallic surfaces Download PDF

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Publication number
US20050263219A1
US20050263219A1 US11/141,157 US14115705A US2005263219A1 US 20050263219 A1 US20050263219 A1 US 20050263219A1 US 14115705 A US14115705 A US 14115705A US 2005263219 A1 US2005263219 A1 US 2005263219A1
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United States
Prior art keywords
plasma
recited
plasma jet
jet
substances
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Abandoned
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US11/141,157
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English (en)
Inventor
Joerg Hoeschele
Dirk Kiesel
Juergen Steinwandel
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MTU Aero Engines AG
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DaimlerChrysler AG
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Assigned to DAIMLERCHRYSLER AG reassignment DAIMLERCHRYSLER AG ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: KIESEL, DIRK, STEINWANDEL, JUERGEN, HOESCHELE, JOERG
Publication of US20050263219A1 publication Critical patent/US20050263219A1/en
Assigned to DAIMLER AG reassignment DAIMLER AG CHANGE OF NAME (SEE DOCUMENT FOR DETAILS). Assignors: DAIMLERCHRYSLER AG
Assigned to MTU AERO ENGINES GMBH reassignment MTU AERO ENGINES GMBH ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: DAIMLER AG
Priority to US12/800,859 priority Critical patent/US20100288399A1/en
Abandoned legal-status Critical Current

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    • H—ELECTRICITY
    • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05H—PLASMA TECHNIQUE; PRODUCTION OF ACCELERATED ELECTRICALLY-CHARGED PARTICLES OR OF NEUTRONS; PRODUCTION OR ACCELERATION OF NEUTRAL MOLECULAR OR ATOMIC BEAMS
    • H05H1/00—Generating plasma; Handling plasma
    • H05H1/24—Generating plasma
    • H05H1/26—Plasma torches
    • H05H1/30—Plasma torches using applied electromagnetic fields, e.g. high frequency or microwave energy
    • C—CHEMISTRY; METALLURGY
    • C21—METALLURGY OF IRON
    • C21D—MODIFYING THE PHYSICAL STRUCTURE OF FERROUS METALS; GENERAL DEVICES FOR HEAT TREATMENT OF FERROUS OR NON-FERROUS METALS OR ALLOYS; MAKING METAL MALLEABLE, e.g. BY DECARBURISATION OR TEMPERING
    • C21D1/00—General methods or devices for heat treatment, e.g. annealing, hardening, quenching or tempering
    • C21D1/06—Surface hardening
    • C21D1/09—Surface hardening by direct application of electrical or wave energy; by particle radiation
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22F—CHANGING THE PHYSICAL STRUCTURE OF NON-FERROUS METALS AND NON-FERROUS ALLOYS
    • C22F1/00—Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working
    • C22F1/02—Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working in inert or controlled atmosphere or vacuum
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22F—CHANGING THE PHYSICAL STRUCTURE OF NON-FERROUS METALS AND NON-FERROUS ALLOYS
    • C22F1/00—Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working
    • C22F1/04—Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working of aluminium or alloys based thereon
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22F—CHANGING THE PHYSICAL STRUCTURE OF NON-FERROUS METALS AND NON-FERROUS ALLOYS
    • C22F3/00—Changing the physical structure of non-ferrous metals or alloys by special physical methods, e.g. treatment with neutrons

Definitions

  • the present invention relates to a method for remelting metallic surfaces using the effect of a high pressure plasma jet, the surface being melted in localized areas and having a structure refinement after solidification, the plasma jet action being generated by the microwave impact on a carrier gas and the pressure of the high pressure plasma jet being above the atmospheric pressure.
  • alloy remelting represents a known method for enhancing the surface hardness, the surface strength, or the surface ductility.
  • the change in the material properties is based on structure transformation which is caused by melting and quenching processes.
  • the quick solidification of the melted surface layer is accompanied by structure transformation, a grain refinement for example, or the formation of metastable phases. It is frequently only necessary to treat the surface layer in localized areas of the material and to leave the base material outside these function surfaces unchanged.
  • laser remelting Different high-performance jet methods, such as laser remelting, are known for treating the surface layer of a work piece.
  • the laser remelting method is associated with high investment and operating costs.
  • Plasma jet methods are also known as additional methods.
  • the plasma jet methods are typically high-performance micro jet methods having the disadvantage of low jet quality and low power density. It is also disadvantageous that the choice of the type of plasma gas is very limited. Gases or gas mixtures of Ar, H 2 , and N 2 are the only common choices. Due to the system inertia, regulation of the gas supply and the power may only take place in a delayed manner—the delay in plasma jet methods is several seconds at best.
  • alloy remelting methods do not conform to the increasing demands placed on the mass production of components with larger dimensions.
  • alloy remelting methods directed in particular to increasing the strength and ductility of work pieces or components which are subjected to thermal-mechanical stress (TMF thermal-mechanical fatigue), are becoming increasingly important in order to replace the expensive coating methods. This is true, for example, for valve bars and/or valve seats of a light metal cylinder head.
  • a method for manufacturing a cylinder head for an internal combustion engine using an Al casting alloy is known from DE 3605519 A1, for example, in which, by directing energy of high power density such as a tungsten inert gas arc or laser energy, the surface of the aluminum alloy is melted and quickly cooled down again to solidify.
  • Laser energy, plasma arcs, and electron beams are cited as further energy sources.
  • the described methods have the disadvantage that the energy sources used allow only low power densities, i.e., achieving high power densities involves substantial complexity with regard to equipment. This represents a disadvantage for the mass production of components to be remelted since this is associated in particular with long processing times and high processing costs.
  • the focusing and stabilizing of conventional plasma jets are problematic at high plasma energy densities.
  • Current plasma jet methods are pure surface methods and are not suitable for the remelting of deeper-lying areas of the surface.
  • An object of the present invention is to provide a method for remelting metallic surfaces of components having energy densities on the metal surface in order to make shorter processing times possible in particular.
  • a further or alternate object of the present invention is to provide a suitable plasma torch.
  • the present invention provides a method for remelting metallic surfaces of components using the effect of a stable high pressure plasma jet, the surface being melted in localized areas and having a structure refinement after solidification, wherein the plasma jet ( 9 ) is generated by the microwave impact on a carrier gas, the pressure of the high pressure plasma jet being above the atmospheric pressure.
  • the present invention provides a plasma torch for generating a directed high pressure plasma jet including a gas supply, a device for generating a plasma, and an outlet nozzle for a plasma jet, wherein the device for generating the plasma includes a magnetron ( 13 ) and a resonator ( 5 ) in which the supplied pressurized carrier gas is transferred into a plasma under the effect of microwaves, causing the plasma to exit through the outlet nozzle ( 3 ) at a pressure above 0.1 MPa.
  • the device for generating the plasma includes a magnetron ( 13 ) and a resonator ( 5 ) in which the supplied pressurized carrier gas is transferred into a plasma under the effect of microwaves, causing the plasma to exit through the outlet nozzle ( 3 ) at a pressure above 0.1 MPa.
  • the method according to the present invention provides that, for remelting metallic surfaces, a stable high pressure plasma jet is directed over the surface of the component, the surface being melted in localized areas due to the impact of this stable high pressure plasma jet and having a structure refinement after solidification.
  • the plasma jet action is generated by the microwave impact on a carrier gas, the pressure of the high pressure plasma jet being above the atmospheric pressure.
  • This method has the advantage that a high energy density, i.e., power density of the jet, may be achieved on the component's surface.
  • the high power density depends in particular on the high pressure, i.e. the high density of the plasma gas. Due to the density, the number of energy-transferring gas atoms or molecules per volume unit is increased.
  • the pressure of the plasma jet, at least at the outlet aperture is above 0.1 MPa, preferably in the 0.1 MPa to 0.8 MPa range, particularly preferably in a 0.15 MPa to 0.4 MPa range. Too high a pressure is difficult to achieve by the equipment. And also, too high a pressure of the plasma jet results in an undesirable blowing of the melted surface.
  • a further advantageous effect of the high pressure method is the fact that the microwave source enters the carrier gas with a high thermal degree of efficiency.
  • the pressure in the microwave device, generated by a microwave resonator in particular, is preferably in the 0.1 MPa to 0.8 MPa range.
  • Another advantage of the present invention is the fact that the selection of carrier gases, which form the plasma jet, is hardly limited.
  • inert gases and reactive gases are the gases Ar, He, N 2 , H 2 , O 2 , CO 2 , H 2 O, CH 4 , and/or C 2 H 6 , which may be found in pure form or in different gas mixtures with each other.
  • Air is used as the carrier gas in a preferred embodiment of the present invention.
  • inert gases Ar in particular, are preferred carrier gases.
  • reactive gases such as O 2 , N 2 , or H 2 O
  • a partial reaction of the superficial light metal with the reactive gas takes place. This causes light metal oxides in particular, or nitrides, e.g., Al 2 O 3 or AlN, to be formed. These ceramic reaction products are incorporated into the remelted surface layer, causing an advantageous dispersion gain.
  • a further advantage of the method according to the present invention is the fact that a comparatively stable plasma jet is used which is able to be accurately directed onto the surface of the component to be treated. Furthermore, it is possible to geometrically modify the gas dynamics of the plasma jet, i.e., to fan out, for example, or to focus it.
  • a filament-shaped plasma jet having a length above 5 cm is used.
  • the plasma jet has a diameter in the 0.5 cm to 5 cm range and a length in the 10 cm to 40 cm range.
  • the method according to the present invention for remelting metallic surfaces is advantageous in particular when components made of light metal alloys are used. This includes the current aluminum alloys.
  • the components which are able to be handled particularly advantageously using the method according to the present invention include cylinder heads in particular.
  • the energy, entered via the plasma jet is preferably set in such a way that a cooling rate in the 20 K/sec to 110 K/sec range is achieved.
  • the remelting is preferably set in such a way that a structure in the T7 state is formed.
  • the remaining cylinder head typically has a T6 structure.
  • the remelted surface layer preferably has a thickness, i.e. depth, in the range of a few 100 ⁇ m to a few mm.
  • a thickness is preferably set which is in the 0.5 mm to 1.5 mm range.
  • due to the method according to the present invention using a high pressure plasma jet it is also possible to set considerably thicker layers, in the range of several mm for example, without great additional costs. This may be an advantage if, for example after remelting, targeted areas of the surface should be remachined to remove chips without the remelted material layer becoming completely lost.
  • the plasma jet has a comparatively high power density in order to be able to implement short processing times.
  • the surface is preferably treated using a plasma jet having a power density in the 6 kW/cm 2 to 20 kW/cm 2 range, the jet being moved over the surface at a speed of 2 mm/sec to 4 mm/sec.
  • the plasma jet has a power density in the 20 kW/cm 2 to 60 kW/cm 2 range and is moved over the surface at a speed of 2 mm/sec to 10 mm/sec.
  • solid or liquid substances are supplied to the plasma jet close to the nozzle outlet aperture. This may take place either prior or subsequent to opening the nozzle. In terms of design, it must be borne in mind that remixing of the supplied substances into the gas chamber of the resonator is largely impossible.
  • the solid substances are formed by ceramic powders. These particles preferably have a nano structure and have particle sizes essentially below approximately 1 ⁇ , in particular below approximately 500 nm.
  • the ceramic particles are inserted into the melted surface layer via the plasma jet and are dispersed in the melt layer, causing a dispersion gain of the metal layer.
  • An increase in particular in vibrostability under thermo mechanical stress of the local surface area is achieved via the nano-structured particles.
  • the increase in vibrostability is based on the dispersion gain of the local area of the surface layer due to the finely distributed nano-structured particles as well as on the dependency of the yield point from the grain refinement (Hall-Petch relationship) which is brought about by the remelting process.
  • the preferred ceramic particles include oxides such as Al 2 O 3 , or nitrides such as AlN, Si 3 N 4 and/or carbides such as SiC.
  • the solid or liquid substances are preferably supplied to the plasma jet via a ring nozzle.
  • the use of a ring nozzle results in a homogenization of the nano-structured particles in the plasma jet as well as in the melted surface layer of the metallic work piece.
  • the liquid substances may be supplied in an analogous manner.
  • the preferred liquid substances include solutions of metal salts, e.g., metal hydroxides or metal carboxylic acid salts, or solutions of metal-organic compounds, e.g., silanes, carbosilanes, or metal chelate compounds.
  • the liquid substances decompose under the plasma jet's conditions into the corresponding metal oxides, metal nitrides, or metal carbides. These act in an analogous manner as the supplied ceramic particles.
  • the particles supplied via the decomposition of the liquid substances are generally distinctly finer than those obtainable via the supply of the solid substances.
  • Another aspect relates to the application of the remelting method via high pressure plasma jet on components made of light metal alloy.
  • a preferred application is the remelting of surface layers of cylinder heads, preferably in the valve bar and/or valve seat area(s).
  • Another aspect of the present invention relates to a device for generating a high pressure plasma jet, hereinafter referred to as a plasma torch, using microwave energy.
  • FIG. 1 shows a schematic representation of a plasma torch including short-circuiting plunger ( 1 ), aperture ( 2 ), nozzle ( 3 ), observation window ( 4 ), resonator ( 5 ), inspection glass ( 6 ), gas feeder ( 7 ), glass holder ( 8 ), plasma jet ( 9 ), water load ( 10 ), circulator ( 11 ), frequency tuner ( 12 ), and magnetron ( 13 ); and
  • FIG. 2 shows the remelting process including melted surface layer ( 11 ), metallic surface of a component ( 21 ), supply device ( 31 ), supplied particles ( 41 ), and plasma jet ( 9 ).
  • the carrier gas is supplied to the plasma torch via a gas feeder ( 7 ) for generating a directed high pressure plasma jet. At least during the feeding of microwave energy, the gas is pressurized with an overpressure. A pressure above 0.1 MPa is preferably set, particularly preferred in the 0.2 MPa to 0.8 MPa range.
  • the microwave energy is generated in a magnetron ( 13 ) and acts on the carrier gas in resonator ( 5 ). Common frequencies are around 0.95 GHz to 12 GHz. A frequency of 2.45 GHz is particularly preferred.
  • the output of the magnetron depends in particular on the intended power density of the plasma jet. Typical values are in the 1 kW to 20 kW range.
  • the microwaves are conducted to resonator ( 5 ) via a hollow conductor system and generate the plasma by resonant coupling.
  • the generated plasma exits under pressure to the outside via nozzle ( 3 ) and aperture ( 2 ) and forms a stable plasma jet ( 9 ).
  • the nozzle may have an expansion device in the direction of the jet.
  • the plasma jet is preferably further stabilized via a swirl stabilization of the working gas. This makes very exact jet geometries possible, e.g., filament-shaped high pressure plasma jets.
  • a further embodiment of the plasma torch according to the present invention provides devices which magnetohydrodynamically stabilize the highly ionized plasma. Electromagnetic apertures in the outlet area of the plasma jet are provided for this purpose, for example.
  • the torch according to the present invention is characterized by a long service life and high operating reliability due to its microwave energy source.
  • the supply of solid particles ( 41 ) to plasma jet ( 9 ) close to the plasma cone on the surface ( 21 ) to be remelted is schematically shown in FIG. 2 .
  • a ring nozzle around plasma jet ( 9 ) is provided in a further advantageous embodiment of the supply device.
  • Plasma jet ( 9 ) and the particle or liquid jet preferably run concentrically to one another.
US11/141,157 2004-06-01 2005-05-31 Device and method for remelting metallic surfaces Abandoned US20050263219A1 (en)

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Application Number Priority Date Filing Date Title
US12/800,859 US20100288399A1 (en) 2004-06-01 2010-05-24 Device and method for remelting metallic surfaces

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
DE102004026636A DE102004026636B3 (de) 2004-06-01 2004-06-01 Vorrichtung und Verfahren zum Umschmelzen von metallischen Oberflächen
DE102004026636.0 2004-06-01

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US12/800,859 Continuation US20100288399A1 (en) 2004-06-01 2010-05-24 Device and method for remelting metallic surfaces

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US (2) US20050263219A1 (de)
DE (1) DE102004026636B3 (de)
FR (1) FR2870857B1 (de)
GB (1) GB2414742B (de)
IT (1) ITRM20050250A1 (de)

Cited By (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20100320197A1 (en) * 2009-06-18 2010-12-23 Babcock & Wilcox Technical Services Y-12, Llc Fluidized bed heat treating system
US20110143484A1 (en) * 2009-12-14 2011-06-16 Industrial Technology Research Institute Method of fabricating solar cell
WO2014184007A1 (de) 2013-05-17 2014-11-20 G. Rau Gmbh & Co. Kg Verfahren und vorrichtung zum umschmelzen und/oder umschmelzlegieren metallischer werkstoffe, insbesondere von nitinol
CN110592416A (zh) * 2019-10-24 2019-12-20 沈阳工业大学 一种等离子体辅助气体合金化的方法
RU2740548C1 (ru) * 2019-11-26 2021-01-15 Федеральное государственное бюджетное образовательное учреждение высшего образования "Казанский национальный исследовательский технический университет им. А.Н. Туполева-КАИ" (КНИТУ-КАИ) Способ упрочнения листа из сплава на основе железа

Families Citing this family (2)

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Publication number Priority date Publication date Assignee Title
US20140261283A1 (en) * 2013-03-14 2014-09-18 Federal-Mogul Corporation Piston and method of making a piston
CN113862593B (zh) * 2021-10-18 2022-10-21 天津大学 一种基于等离子体改性提升软质金属表面加工质量的方法

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US6132653A (en) * 1995-08-04 2000-10-17 Microcoating Technologies Chemical vapor deposition and powder formation using thermal spray with near supercritical and supercritical fluid solutions
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US6940036B2 (en) * 2001-07-28 2005-09-06 Mtu Aero Engines Gmbh Laser-plasma hybrid welding method
US6982395B2 (en) * 2001-03-15 2006-01-03 Mtu Aero Engines Gmbh Method and apparatus for plasma welding with low jet angle divergence

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US4652723A (en) * 1983-11-17 1987-03-24 L'air Liquide, Societe Anonyme Pour L'etude Et Lexploitation Des Procedes Georges Claude Method for heat treating with a microwave plasma torch
US4535212A (en) * 1984-07-06 1985-08-13 Tocco, Inc. Apparatus and method of hardening valve seats
US4695329A (en) * 1985-02-21 1987-09-22 Toyota Jidosha Kabushiki Kaisha Method for manufacturing a cylinder head of cast aluminum alloy for internal combustion engines by employing local heat treatment
US5793013A (en) * 1995-06-07 1998-08-11 Physical Sciences, Inc. Microwave-driven plasma spraying apparatus and method for spraying
US6132653A (en) * 1995-08-04 2000-10-17 Microcoating Technologies Chemical vapor deposition and powder formation using thermal spray with near supercritical and supercritical fluid solutions
US6734385B1 (en) * 1999-05-11 2004-05-11 Dae Won Paptin Foam Co. Ltd. Microwave plasma burner
US6982395B2 (en) * 2001-03-15 2006-01-03 Mtu Aero Engines Gmbh Method and apparatus for plasma welding with low jet angle divergence
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Cited By (13)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20100320197A1 (en) * 2009-06-18 2010-12-23 Babcock & Wilcox Technical Services Y-12, Llc Fluidized bed heat treating system
WO2010147943A1 (en) * 2009-06-18 2010-12-23 Babcock & Wilcox Technical Services Y-12, Llc Fluidized bed heat treating system
US8716637B2 (en) 2009-06-18 2014-05-06 Babcock & Wilcox Technical Services Y-12, Llc Fluidized bed heat treating system
US20110143484A1 (en) * 2009-12-14 2011-06-16 Industrial Technology Research Institute Method of fabricating solar cell
US8124535B2 (en) * 2009-12-14 2012-02-28 Industrial Technology Research Institute Method of fabricating solar cell
TWI472049B (zh) * 2009-12-14 2015-02-01 Ind Tech Res Inst 太陽能電池的製造方法
DE102013008396A1 (de) * 2013-05-17 2014-12-04 G. Rau Gmbh & Co. Kg Verfahren und Vorrichtung zum Umschmelzen und/oder Umschmelzlegieren metallischer Werkstoffe, insbesondere von Nitinol
WO2014184007A1 (de) 2013-05-17 2014-11-20 G. Rau Gmbh & Co. Kg Verfahren und vorrichtung zum umschmelzen und/oder umschmelzlegieren metallischer werkstoffe, insbesondere von nitinol
DE102013008396B4 (de) * 2013-05-17 2015-04-02 G. Rau Gmbh & Co. Kg Verfahren und Vorrichtung zum Umschmelzen und/oder Umschmelzlegieren metallischer Werkstoffe, insbesondere von Nitinol
DE202014011248U1 (de) 2013-05-17 2018-10-25 G. Rau Gmbh & Co. Kg Vorrichtung zum Umschmelzen und/oder Umschmelzlegieren metallischer Werkstoffe, insbesondere von Nitinol, und entsprechende Halbzeuge
US10422018B2 (en) 2013-05-17 2019-09-24 G. Rau Gmbh & Co. Kg Method and device for remelting and/or remelt-alloying metallic materials, in particular Nitinol
CN110592416A (zh) * 2019-10-24 2019-12-20 沈阳工业大学 一种等离子体辅助气体合金化的方法
RU2740548C1 (ru) * 2019-11-26 2021-01-15 Федеральное государственное бюджетное образовательное учреждение высшего образования "Казанский национальный исследовательский технический университет им. А.Н. Туполева-КАИ" (КНИТУ-КАИ) Способ упрочнения листа из сплава на основе железа

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US20100288399A1 (en) 2010-11-18
ITRM20050250A1 (it) 2005-12-02
GB2414742A (en) 2005-12-07
FR2870857B1 (fr) 2007-04-20
GB2414742B (en) 2006-08-02
FR2870857A1 (fr) 2005-12-02
DE102004026636B3 (de) 2005-07-21
GB0510896D0 (en) 2005-07-06

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