US20070235003A1 - Piston formed by powder metallurgical methods - Google Patents
Piston formed by powder metallurgical methods Download PDFInfo
- Publication number
- US20070235003A1 US20070235003A1 US11/224,269 US22426905A US2007235003A1 US 20070235003 A1 US20070235003 A1 US 20070235003A1 US 22426905 A US22426905 A US 22426905A US 2007235003 A1 US2007235003 A1 US 2007235003A1
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- United States
- Prior art keywords
- piston
- assembly
- skirt
- pin
- crown
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- Abandoned
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Classifications
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F5/00—Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product
- B22F5/008—Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product of engine cylinder parts or of piston parts other than piston rings
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F7/00—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression
- B22F7/06—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression of composite workpieces or articles from parts, e.g. to form tipped tools
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F02—COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
- F02F—CYLINDERS, PISTONS OR CASINGS, FOR COMBUSTION ENGINES; ARRANGEMENTS OF SEALINGS IN COMBUSTION ENGINES
- F02F3/00—Pistons
- F02F3/0084—Pistons the pistons being constructed from specific materials
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F02—COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
- F02F—CYLINDERS, PISTONS OR CASINGS, FOR COMBUSTION ENGINES; ARRANGEMENTS OF SEALINGS IN COMBUSTION ENGINES
- F02F3/00—Pistons
- F02F3/26—Pistons having combustion chamber in piston head
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F2998/00—Supplementary information concerning processes or compositions relating to powder metallurgy
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T29/00—Metal working
- Y10T29/49—Method of mechanical manufacture
- Y10T29/49229—Prime mover or fluid pump making
- Y10T29/49249—Piston making
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T29/00—Metal working
- Y10T29/49—Method of mechanical manufacture
- Y10T29/49229—Prime mover or fluid pump making
- Y10T29/49249—Piston making
- Y10T29/49252—Multi-element piston making
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T29/00—Metal working
- Y10T29/49—Method of mechanical manufacture
- Y10T29/49229—Prime mover or fluid pump making
- Y10T29/49249—Piston making
- Y10T29/49256—Piston making with assembly or composite article making
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T29/00—Metal working
- Y10T29/49—Method of mechanical manufacture
- Y10T29/49229—Prime mover or fluid pump making
- Y10T29/49249—Piston making
- Y10T29/49256—Piston making with assembly or composite article making
- Y10T29/49261—Piston making with assembly or composite article making by composite casting or molding
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T29/00—Metal working
- Y10T29/49—Method of mechanical manufacture
- Y10T29/49229—Prime mover or fluid pump making
- Y10T29/49249—Piston making
- Y10T29/49266—Gudgeon pin, wrist pin, piston pin, or boss therefor
Landscapes
- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Chemical & Material Sciences (AREA)
- Manufacturing & Machinery (AREA)
- Combustion & Propulsion (AREA)
- General Engineering & Computer Science (AREA)
- Composite Materials (AREA)
- Materials Engineering (AREA)
- Pistons, Piston Rings, And Cylinders (AREA)
- Powder Metallurgy (AREA)
Abstract
A piston includes a piston structure being unitarily formed in a powder metallurgy process, the piston structure having a crown assembly and a skirt assembly, at least a partial combustion chamber being formed intersecting a piston crown surface during the powder metallurgy process, the skirt assembly depending from the crown assembly and having two spaced apart pin bosses, each pin boss having a pin bore defined therein, a pair of opposed semi-circular skirt members, each skirt member extending outwardly from and being integrally joined to both of the pin bosses. The piston may be formed by executing a powder metallurgy process on at least two different metallic constituents to define a non-homogenous piston structure. A method of forming a piston is further included.
Description
- The present invention relates to components formed by powder metallurgy and, more specifically, to a method and apparatus for forming a piston by powder metallurgy.
- Powder metallurgy is a common manufacturing process used to produce components of high quality for applications, including vehicular engines. Powder metallurgy is often employed in the manufacture of engine components because it is economical, flexible and can produce a finished part that requires much less machining or secondary processing than other methods of forming components. Powder metallurgy allows for a component to be formed of a wide variety of alloys, composites, and other materials to provide the finished component with desirable characteristics. Moreover, powder metallurgy allows the porosity of a part to be controlled for lubricant impregnation. Powder metallurgy is well suited to manufacture parts of a wide range of sizes and shapes. Also, powder metallurgy can reliably produce parts with consistent dimensions and advantageous physical properties.
- The powder metallurgy manufacturing process is often employed to form engine components. However, no examples of a piston, formed homogeneously or non-homogeneously, by a powder metallurgy forging process are known. Such a piston would provide substantial benefits in the industry over the present forged steel and cast aluminum pistons.
- The art of making pistons is old and crowded. Nonetheless, considerable inventive effort continues to the present in order to form pistons having advantageous characteristics. A recent example is U.S. Pat. No. 6,435,077, issued Aug. 20, 2002, to Damour et al. The Damour reference discloses an integral, unitary piston wherein the pin bosses are carefully formed in order to permit a working tool to be inserted between the two bosses in order to form a relatively large cavity beneath the center post of the combustion chamber formed in the crown of the piston. It would be advantageous to form a piston that minimized the amount of machining that was necessary subsequent to initial formation of the piston in order to achieve the desired shape.
- A second recent example of piston technology found in U.S. Pat. No. 6,279,455, issued Aug. 28, 2001, to Kruse. The Kruse reference discloses a piston in which the crown has an upper portion and a lower portion formed separately and then joined along specific faces to form a two piece crown of the piston. It would be advantageous to form a suitable piston in a single operation to minimize the complexity of suitably joining two portions of the crown and yet achieve a satisfactory piston structure.
- The present invention substantially meets the aforementioned needs of the industry. A piston formed by the process of the present invention is unitary and integral, formed of a single operation. Particular attention has been paid to certain bends and radii in the undercrown region that make the piston more forgeable. Additionally, significantly less material is utilized in the process compared with a traditional forging. It should be noted that a bowl forming at least a partial combustion chamber in the crown of the piston may be formed during the powder metallurgy forging process of the piston. The combustion chamber bowl may include valve pockets in the forging.
- The present invention is a piston including a piston structure being unitarily formed in a powder metallurgy process, the piston structure having a crown assembly and a skirt assembly, at least a partial combustion chamber being formed intersecting a piston crown surface during the powder metallurgy process, the skirt assembly depending from the crown assembly and having two spaced apart pin bosses, each pin boss having a pin bore defined therein, a pair of opposed semi-circular skirt members, each skirt member extending outwardly from and being integrally joined to both of the pin bosses. The piston may be formed by executing a powder metallurgy process on at least two different metallic constituents to define a non-homogenous piston structure. A method of forming a piston is a further aspect of the present invention.
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FIG. 1 is a perspective side view of a piston made in accordance with the present invention; -
FIG. 2 is a perspective undercrown view of the piston ofFIG. 1 ; -
FIG. 3 is a partial cutaway perspective view of a vehicular engine including an exemplary embodiment of a piston made in accordance with the present invention; -
FIG. 4 is a process flowchart for a powder metallurgy manufacturing process for forming the piston ofFIG. 1 ; -
FIG. 5 is a process flowchart for fabricating a non-homogenous component using the powder metallurgy manufacturing process according to an embodiment of the present invention; -
FIG. 6 is a side cutaway view of the green part forming apparatus according to an embodiment of the present invention; -
FIG. 7 is a front view of a green part forming apparatus according to an embodiment of the present invention; -
FIG. 8 is a top view of a green part forming apparatus according to an embodiment of the present invention; -
FIG. 9 is a partial top cutaway detailed view of a feed valve for a green part forming apparatus according to an embodiment of the present invention; -
FIG. 10 is a partial cutaway side detailed view of a powder egress in the open position according to an embodiment of the present invention; -
FIG. 11 is a partial cutaway side detailed view of a powder egress in the closed position according to an embodiment of the present invention; -
FIG. 12 is a process flowchart for fabricating a non-homogenous component using the powder metallurgy manufacturing process according to an embodiment of the present invention; -
FIG. 13 is a side cutaway view of the green part forming apparatus according to an embodiment of the present invention; and -
FIG. 14 is a side cutaway view of the green part forming apparatus according to an embodiment of the present invention. - The piston of the present invention is shown generally at 10 in
FIGS. 1 and 2 . Thepiston 10 of the present invention has two major subcomponents:crown assembly 250 andskirt assembly 252. - The
crown assembly 250 of thepiston 10 presents atop margin 254. At least a partial combustion chamber (bowl) 256 is defined in the top margin (crown surface) 254. Thecombustion chamber 256 is preferably centrally defined in thepiston 10 such that a central axis of thecombustion chamber 256 is coincident with a central axis of thepiston 10. Valve clearance (pockets not shown) may be forged into thecombustion chamber 256, as desired. Additionally, secondary machining may be employed after the forging of thepiston 10 in order to define the desiredcombustion chamber 256. - An
exemplary combustion chamber 256 preferably has an annularreentrant surface 258. The annularreentrant surface 258 preferably smoothly transitions to an annular orspherical side margin 260. Theside margin 260 in turn preferably smoothly transitions to an annular orspherical bottom margin 262. Acenter post 264, which is preferably spherical, is smoothly joined to thebottom margin 262. - The
crown assembly 250 includes aside margin 268. As forged, theside margin 268 may be smooth. A plurality of grooves includingcompression ring grooves 270 andwiper ring groove 272 are depicted formed in theside margin 268. It is understood that secondary machining after forging of thepiston 10 may be necessary to form thecompression ring grooves 270 andwiper ring groove 272. A plurality ofoil passages 274 are formed in the bottom margin of thewiper ring groove 272 to return lubricating oil to the engine oil sump. - A
web 276 is formed on the undercrown of thepiston 10. Theweb 276 is preferably a depending structure that couples thecrown assembly 250 to theskirt assembly 252. - The
skirt assembly 252 includes a pair ofpin bosses 278 a, b, each pin boss 278 depending from theweb 276. Each of thepin bosses 278 a, b has a substantially planarouter margin 280 and an inclinedinner margin 282. The inclinedinner margin 282 is thicker at the point of juncture with theweb 276 than at the lower margin of therespective pin bosses 278 a, b. - A pair of pin bores 284 a, b are in registry and are defined through the
respective pin bosses 278 a, b. The inner margin of the respective pin bores 284 a, b may be formed of as bearing 286 a, b. It is understood that the bearing 286 a, b may simply be a surface formed of the same material as the rest of thepiston 10. Alternatively, the bearing 286 a, b could be separately formed of a different material and affixed in the respective pin bores 284 a, b as by pressing or the like. Such a process is described in greater detail below. Alternatively, a different material may be injected during the powder forging process in the vicinity of thebearings 286 a, b and forged therein at the same time as the forging of the remainder of thepiston 10. Such a process is also described in greater detail below. - Planar lateral extensions 290 a, b extend outward from the
respective pin bosses 278 a, b on both sides of therespective pin bosses 278 a, b. Accordingly, there are four planarlateral extensions 290. Twosemicircular skirts 292 a, b are formed integral with the outer margin of a respective parallel pair of the planarlateral extensions 290. - Each of the
semicircular skirts 292 a, b presents a skirtouter margin 294 that has a radius that is generally equal to the radius of thecrown assembly 250 of thepiston 10. As such, the skirtouter margin 294 presents a bearing surface riding on the inner margin of the cylinder in which thepiston 10 is translationally disposed. - Each of the skirt
outer margins 294 has a dependingskirt lip 296. - Each of the skirt
outer margins 294 presents a skirtupper margin 298. Theupper skirt margin 298 defines in part a lighteningvoid 300 that is defined between the undercrown portion of thecrown assembly 250 and theskirt assembly 252. -
FIG. 3 illustrates the internal detail of a conventional internal combustion engine to illustrate the use of thepiston 10. Connectingrod 64 is pivotally connected to thepiston 10 and to thecrankshaft 74. The connectingrod 64 is connected to thecrankshaft 74 at a large or crankend 76. Thelarge end 76 of therod 64 receives a shaft portion (“crank pin”) 78 of thecrankshaft 74. The connectingrod 64 is further connected to thepiston 10 at a small or piston end 70 of therod 64. A pin (“wristpin”) 68 is used to rotatably secure thesmall end 70 of the connectingrod 64 within the skirt portion of thepiston 66. - Referring to
FIG. 4 , a process chart for a powder metallurgicalcomponent forming process 30 is shown that is suitable to form a homogeneous embodiment of thepiston 10. First, the metal powders 32 that will comprise the component (piston 10 of the present invention) are provided. Often, lubricants are added to the metal powders to decrease the wear of pressing machinery. Next, the base powders are mixed 34 to form a homogenous mixture. Thefinished piston 10 will ultimately be a homogeneous alloy of the constituent metal powders. - A mold or die is then filled 36 with the mixed powders. The die, when closed, has an internal cavity in the same shape as the final part,
piston 10. The powder is compressed 38 within the die to form a so-called “green part”, which has the substantially the shape of thefinished piston 10. Thecompaction 38 is usually performed at room temperature and at pressures in the range of 30-50 tons per square inch. The green part, also referred to as a “green compact,” has the desired size and shape of thefinished piston 10 when ejected from the die. Aftercompaction 38, the green part has sufficient strength for further processing. - Next, the green part is subjected to a
sintering process 40. Generally, sintering 40 involves subjecting the green part to a temperature of 70-90% of the melting point of the metal or alloy comprising the green part. The variables of temperature, time and atmosphere are controlled in the furnace to produce a sintered part having improved strength due to bonding or alloying of the metal particles. Thesintering process 40 most generally comprises three basic steps conducted in a sintering furnace: (a)burnoff 46; (b)sinter 48; and (c) cooling 50. Continuous-type sintering furnaces are commonly used to perform these steps.Burnoff 46 is performed in a burnoff chamber and is used to volatize the lubricants used in forminggreen part 10. A high-temperature chamber performs theactual sintering 48. The cooling chamber performs the cooling 50 and cools thesintered part 10 prior to handling. - The
pistons 10 that exit thesintering furnace 40 after cooling 50 may be considered complete. Alternatively, they may undergo one or moresecondary operations 42. Exemplary secondary operations include re-pressing thecomponent 52, machining 54, tumbling 56 and joining the component withadditional components 58 as part of an overall assembly. Thesecondary operations 42 may also include the impregnation of oils orlubricants 60 into the part for conveying self-lubricating properties. The sintered component may also undergoheat treatment 62 to provide certain characteristics and properties to the component, such as strength. Those skilled in the art will recognize that other secondary operations may be performed. Thesecondary operations 42 may be performed individually or in combination with other secondary operations. - After sintering 40, a variety of
secondary operations 42 may be performed on the part depending its intended use. It is understood that thebearings 286 a, b may be formed of the homogenous material forming the remainder of thepiston 10, However, a separate component defining a bearing 286 a, b may be disposed in the wrist pin aperture bore 284 a, b ofFIGS. 1 and 2 by pressing into the pin bore 284 a, b. The bearing 286 a, b may be formed of bronze or other material suitable to provide the rotating contact with thewrist pin 68. In certain uses, the material forming the bearing may advantageously be a different material than that forming the remainder of thepiston 10. Finally, thefinished piston 10 is ready for employment. -
FIG. 5 illustrates the process for manufacturing a non-homogenous powder metallurgical manufacturedpiston 10. Afirst metal powder 100 is provided to amold 102. Then, asecond metal powder 104 is provided to themold 106. The powder in themold 106 is next pressed 108 to form a green part comprising thepiston 10. Thegreen part 10 is then sintered 110 before performing one or moresecondary operations 112. After thegreen part 10 is sintered 110 and allsecondary operations 112 performed, the part is then finished 114. This process may be modified as shown instep 107 by providing a first metal powder to the mold following the provision of thesecond metal powder 104 to themold 106. Those skilled in the art will recognize that additional layering of powdered metals may be performed without deviating from the spirit and scope of the present invention. - The above procedure is performed to provide a
piston 10 with dissimilar characteristics at discrete locations in thepiston 10. For example, thepiston 10 may be provided with a unitary layer of material forming thebearings 286 a, b by way of the forming operation. The method of manufacturing thepiston 10 by the present method allows the secondary step of separately forming and providingwrist pin bearings 286 a, b to be eliminated, thereby saving cost, time, and complexity. The bearing 286 a, b is instead formed integrally during the powder forging process, as described in greater detail below. - Referring to
FIG. 7 , a greencomponent forming apparatus 120 according to an embodiment of the present invention is shown. The greenpart forming apparatus 120 may be referred to generally as afeedshoe apparatus 120. Thefeedshoe apparatus 126 most generally comprises apowder filling vessel 122 actuatable by anactuator cylinder 134, anupper punch 140, alower punch 142, and apowder hopper 148. More particularly, afirst vessel 122 is rigidly connected to asecond vessel 126 by one ormore connection members 138. Thesecond vessel 126 is connected to anactuator cylinder 134 via apiston 136. Theactuator cylinder 134 may be a hydraulic or pneumatic cylinder for urging thepiston 136 in or out, thereby guiding first 124 and second 125 vessels in a linearly controlled movement. Eachvessel side walls 125 defining aninterior cavity side walls 125 have slopedportions 129 for directing powder towards apowder outlet valve 146. Atop opening 127 in thevessel chute hopper hoppers interior cavity 124 and secondinterior cavity 128. Thefirst chute 152 andsecond chute 154 comprise a flexible tube configured to allow for the linear movement of thefirst vessel 122 andsecond vessel 126. Both first andsecond vessels bridge member 132. Each of thebridge member 132 andactuator cylinder 134 are mounted on a die table 130. - Referring to
FIG. 7 , a side view of thefeedshoe apparatus 120 is depicted. One ormore locking mechanisms 160 are provided to the die table 130. The lockingmechanisms 160 allow for registration of thevessels die cavity 144 filling operation. Thelocking mechanism 160 may be a magnet or other locking means such as a male-female socket or equivalent thereto. - The
bridge member 132 is slidably disposed on theguides 166. Eachguide 166 is further disposed upon arail 168. Anelevation cylinder 162 is disposed on eachbridge member 132 and configured to elevate thebridge member 132 above theguides 166 by extension of anelevation piston 154. The separation shown inFIG. 2 between thefirst vessel 122 and thedie cavity 144 allows theactuator cylinder 162 to move thevessel 122 transverse to thecavity 144. Thevessels punches - Referring to
FIG. 8 , a top view of thefeed shoe apparatus 120 is shown. Eachvessel die cavity perimeter 172 is shown for reference purposes. One or more powder egresses 170 are disposed in the bottom surface of eachvessel valves 148 for controlling the passing of the powder metal into thedie cavity 144. Theegresses 170 may be sized to control the relative amount of flow through aparticular egress 170 during a filling operation. Thefirst vessel 122 is shown with asingle egress 170. Thesecond vessel 126 is shown as having threeegresses 170 with differing sizes. Various polygonal or eccentric shapes or varying size may be employed in place of the circular-shaped egresses without departing from the scope of the present invention. - The size and placement of the powder egresses 170 are carefully chosen to correspond with the provision of predetermined characteristics for the finished part. For example, the
piston 10 in an internal combustion engine needs to include abearing race 286 a, b as part of the pin bores 284 a, b. As noted above, the method for manufacturing thepiston 10 is to provide separately formedbearings 286 a, b to the preformedpiston 10 as part of a secondary operation. The apparatus and method disclosed herein provides for a powder egress positioned at the precise location for thebearing race 286 a, b portion of thepiston 10. - The feedshoe apparatus shown in
FIG. 8 additionally includes aliquid injection apparatus 174. Theliquid injection apparatus 174 injects liquids to the firstinterior cavity 124 during a forming process. An inlet to theinjection apparatus 176 is connected to aliquid conduit 178, which supplies a liquid solution. The apparatus may comprise a solenoid valve, such as a zero dead leg volume solenoid valve. However, a variety of suitable dripless valves may be used without departing from the scope of the present invention. Those of skill in the art will recognize that the present invention may also be practiced with a second liquid injection apparatus provided to the second vessel, or alternatively, one liquid injection apparatus in communication with both of the first and second vessels. - The liquid solution may include aqueous solutions, lubricants, surfactants, or activation solutions for cleaning metal particulates for cold welding. The liquid solution may also include any solution that is intended to be incorporated into the material, such as a hardener, or solvent. The injection of lubricants may be employed to reduce wear to the die cavity of the apparatus.
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FIG. 9 illustrates avalve assembly 148 that comprises thepowder egress 170 of thevessel housing surface 182 in conjunction withslide hole 124 define an open position P1 and a closed position P2 for thepowder egress 170. Theslide hole 184 moves between positions P1 and P2 as theactuator 134 linearly translates thevessel - Referring to
FIGS. 10 and 11 , depict an alternative embodiment of an apparatus and method for controlling the flow of metal powder into thedie cavity 144. Afeedtube 186 communicates between theinterior cavity vessel die cavity 144. Thefeedtube 186 is comprised of a flexible material, such as rubber. The bottom sidewall of thevessel channel 188 therein as shown in the figures. A pincher orcrimper device 190 is disposed within thechannel 188. Thefeedtube 186 is in the open position, as shown inFIG. 10 , when the crimpingdevices 190 are withdrawn or not pressing on thetube 186.FIG. 11 shows thetube 186 in a closed position wherein the crimpingdevices 190 press on the tube sidewalls until the sidewalls contact, thereby blocking powder flow. Thecrimpers 190 are urged towards thefeedtube 186 by way of pneumatic control. High pressure is presented to thechannel 188, which urges thecrimpers 190 towards thetube 186. The removal of this high pressure condition causes the natural resiliency of thetube 186 to re-open, thereby permitting powder flow. Mechanical means, such as a linkage, may be used instead of the pneumatic drive means without departing from the intended scope of the present invention. - Referring to
FIGS. 6-8 , the method and apparatus for manufacturing a non-homogeneous article with powder metallurgy will be described in operation. The following description is more particularly directed towards manufacturing apiston 10 for an internal combustion engine wherein thepiston 10 has unitary bearing material formed as bearing 296 a, b as part of a single forming procedure. A first metal powder, such as steel, is placed in thefirst hopper 148 and a second metal powder, such as bronze, is placed in asecond hopper 150. Thefirst vessel 122 is also centered over thedie cavity 144 by either expanding or retracting thepiston 136 of theactuator cylinder 134 as necessary. - Then the first metal powder is introduced to the first
interior cavity 124. The first powder then fills the mold or diecavity 144 through thepowder egress 170 with a predetermined amount of powder. The flow of first powder is stopped by thevalve 148 at thepowder egress 170. Thepiston 136 is next extended until thesecond vessel 126 centers over thedie cavity 144. Note that thepowder egress 170 is not centered over thedie cavity 144. This allows the second powder to deposit at the discreet location needed to form thebearings 286 a, b of thefinished piston 10. A predetermined amount of the second powder is then filled into thedie cavity 144. The first and second powder fill operations are then repeated until thecavity 144 is filled with a sufficient amount of metal powder to form a finished part. - The
piston 136 is next retracted until thefirst vessel 122 is clear of the upper 140 and lower 142 punches. Then the powder in thedie cavity 144 is pressed to form a green part (piston 10) once the clearance has been established. The green part is next placed in a sintering oven and cooled. Once cool, thesintered piston 10 is machined to final tolerances. Other secondary operations, such as carburizing nitriding, or machining, may be performed without departing from the scope of the present invention. It is not necessary to provide thepiston 10 with a separately formed bearing as part of a secondary operation due to the bearing 286 a, b being provided as part of the forming operation. A finished connectingpiston 10 results from the completion of any other required secondary operations. - Referring to
FIG. 12 , an alternative method of manufacturing anon-homogenous piston 10 with anintegral bearing 286 a, b is shown. Each of thefirst metal powder 200 andsecond metal powder 202 is filled in the mold or cavity simultaneously 204. Then the part is pressed 206, sintered 208 and subjected tosecondary operations 210 before it is finished 212. -
FIG. 13 depicts an alternative apparatus for forming a green part (piston 10) according to either the method described inFIG. 5 orFIG. 12 . The feedshoe apparatus according to this embodiment comprises asingle vessel 222. Thevessel 222 comprisessidewalls 223 and acenter divider 224. Thesidewalls 223 andcenter divider 224 define a first section orchamber 226, and a second section orchamber 228. Thefirst section 226 receives a first metal powder from afirst hopper 230 and thesecond section 228 receives a second metal powder from asecond hopper 232. Afirst powder egress 234 is provided to thefirst chamber 226 and asecond powder egress 226 is provided to thesecond chamber 228. - In operation, the first and second powders may be provided to the die cavity at the same time. The respective powder egresses 234, 236 are located and sized to promote the filling of the
cavity 238 with the first and second powders in their desired locations before pressing. Alternatively, thepiston 240 may move thevessel 222 in a linear direction to place a respective first 234 or second 236 egress over a portion of thedie cavity 238 prior to filling with a metal powder. As a further alternative, the powder egresses 234, 236 may be selectively opened and closed to create density gradients in the part or to further place a second material within the first. Additionally, a combination of the above alternatives may be employed as part of the same forming operation. -
FIG. 14 depicts another alternative embodiment of the green part forming (feedshoe)apparatus 250. This embodiment again comprises asingle vessel 252. The vessel comprises first 256 and second 254 dividers for defining a first chamber orsection 258, asecond chamber 260 and athird chamber 262. Eachchamber - The use of three
chambers die cavity 276 in two places simultaneously. Alternatively the threechambers die cavity 276 as part of a single forming operation. The embodiment ofFIG. 14 is operated in substantially the same manner as set forth above for the two-chamber embodiment. - Although the present invention has been described with reference to the preferred embodiments, workers skilled in the art will recognize changes may be made in form and detail without departing from the spirit and scope of the invention.
Claims (14)
1. A piston, comprising:
a piston structure being unitarily formed in a powder metallurgy process, the piston structure having a crown assembly and a skirt assembly, at least a partial combustion chamber being formed intersecting a piston crown surface during the powder metallurgy process, the skirt assembly depending from the crown assembly and having two spaced apart pin bosses, each pin boss having a pin bore defined therein, a pair of opposed semi-circular skirt members, each skirt member extending outwardly from and being integrally joined to both of the pin bosses.
2. The piston of claim 1 , a void being defined between the crown assembly and the skirt assembly.
3. The piston of claim 2 , the void being defined between a skirt member upper margin and an undercrown of the crown assembly.
4. The piston of claim 1 being formed of a homogenous material.
5. The piston of claim 4 , the homogenous material forming a bearing surface of each pin bore for rotatably supporting a wrist pin.
6. The piston of claim 4 , a bearing formed separately of a material distinct from the homogenous material being disposed in each pin bore in a secondary operation for supporting a wrist pin.
7. The piston of claim 1 , the piston structure being unitarily formed in a powder metallurgy process with at least two different metallic constituents providing dissimilar characteristics at discrete locations of the piston structure.
8. The piston of claim 7 , a one of the at least two different metallic constituents presenting a bearing surface defining an inner margin of each pin bore.
9. A piston, comprising:
non-homogenous piston structure being unitarily formed in a powder metallurgy process with at least two different metallic constituents providing dissimilar characteristics at discrete locations of the structure.
10. The piston of claim 9 , a one of the at least two different metallic constituents presenting a bearing surface defining an inner margin of each of two pin bores.
11. The piston of claim 9 , including, the piston structure having a crown assembly and a skirt assembly, at least a partial combustion chamber being formed intersecting a piston crown surface during the powder metallurgy process, the skirt assembly depending from the crown assembly and having two spaced apart pin bosses, each pin boss having a pin bore defined therein, and having a pair of opposed semi-circular skirt members, each skirt member extending outwardly from and being integrally joined to both of the pin bosses.
12. The piston of claim 11 , a void being defined between the crown assembly and the skirt assembly.
13. The piston of claim 12 , the void being defined between a skirt member upper margin and an undercrown of the crown assembly.
14-20. (canceled)
Priority Applications (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US11/224,269 US20070235003A1 (en) | 2003-01-08 | 2005-09-12 | Piston formed by powder metallurgical methods |
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US10/338,500 US6973723B2 (en) | 2003-01-08 | 2003-01-08 | Piston formed by powder metallurgical methods |
US11/224,269 US20070235003A1 (en) | 2003-01-08 | 2005-09-12 | Piston formed by powder metallurgical methods |
Related Parent Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US10/338,500 Division US6973723B2 (en) | 2003-01-08 | 2003-01-08 | Piston formed by powder metallurgical methods |
Publications (1)
Publication Number | Publication Date |
---|---|
US20070235003A1 true US20070235003A1 (en) | 2007-10-11 |
Family
ID=32681465
Family Applications (2)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US10/338,500 Expired - Lifetime US6973723B2 (en) | 2003-01-08 | 2003-01-08 | Piston formed by powder metallurgical methods |
US11/224,269 Abandoned US20070235003A1 (en) | 2003-01-08 | 2005-09-12 | Piston formed by powder metallurgical methods |
Family Applications Before (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US10/338,500 Expired - Lifetime US6973723B2 (en) | 2003-01-08 | 2003-01-08 | Piston formed by powder metallurgical methods |
Country Status (3)
Country | Link |
---|---|
US (2) | US6973723B2 (en) |
AU (1) | AU2003297310A1 (en) |
WO (1) | WO2004063603A2 (en) |
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US20080264376A1 (en) * | 2007-04-27 | 2008-10-30 | Mahle International Gmbh | Piston for an internal combustion engine |
US20090102108A1 (en) * | 2007-10-17 | 2009-04-23 | International Engine Intellectual Property Company, Llc | Cam-action sleeve puller |
US20090194059A1 (en) * | 2007-12-20 | 2009-08-06 | Peter Grahle | Piston for an internal combustion engine and method for its production |
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US20130213340A1 (en) * | 2012-02-20 | 2013-08-22 | Federal Mogul Corporation | Piston assembly for internal combustion engine |
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US9359962B2 (en) | 2012-04-25 | 2016-06-07 | International Engine Intellectual Property Company, Llc | Engine braking |
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US20180266557A1 (en) * | 2015-09-18 | 2018-09-20 | Mahle International Gmbh | Piston for an internal combustion engine |
US20180272429A1 (en) * | 2015-02-06 | 2018-09-27 | Dresser-Rand Company | Methods for Additive Manufacturing of a Single Piece Piston |
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US20080264376A1 (en) * | 2007-04-27 | 2008-10-30 | Mahle International Gmbh | Piston for an internal combustion engine |
US20090102108A1 (en) * | 2007-10-17 | 2009-04-23 | International Engine Intellectual Property Company, Llc | Cam-action sleeve puller |
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CN101966586A (en) * | 2010-10-27 | 2011-02-09 | 河南科技大学 | Piston blank manufacturing method of internal combustion engine |
US9616529B2 (en) | 2011-04-15 | 2017-04-11 | Federal-Mogul Corporation | Piston and method of making a piston |
US20130213340A1 (en) * | 2012-02-20 | 2013-08-22 | Federal Mogul Corporation | Piston assembly for internal combustion engine |
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US9359962B2 (en) | 2012-04-25 | 2016-06-07 | International Engine Intellectual Property Company, Llc | Engine braking |
US9291120B2 (en) * | 2012-09-18 | 2016-03-22 | Federal-Mogul Corporation | Steel piston with counter-bore design |
US20180272429A1 (en) * | 2015-02-06 | 2018-09-27 | Dresser-Rand Company | Methods for Additive Manufacturing of a Single Piece Piston |
WO2017027530A1 (en) * | 2015-08-12 | 2017-02-16 | Schlumberger Technology Corporation | Wear resistant parts and fabrication |
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US20180266557A1 (en) * | 2015-09-18 | 2018-09-20 | Mahle International Gmbh | Piston for an internal combustion engine |
US10711896B2 (en) * | 2015-09-18 | 2020-07-14 | Mahle International Gmbh | Piston for an internal combustion engine |
US20170254290A1 (en) * | 2016-03-01 | 2017-09-07 | Federal-Mogul Llc | Galleryless piston with connection to pockets |
US10352270B2 (en) * | 2016-03-01 | 2019-07-16 | Tenneco Inc. | Galleryless piston with connection to pockets |
CN110337345A (en) * | 2017-02-17 | 2019-10-15 | 天纳克有限责任公司 | Steel pistons and manufacturing method with metallurgical bonding bushing |
Also Published As
Publication number | Publication date |
---|---|
AU2003297310A1 (en) | 2004-08-10 |
WO2004063603A2 (en) | 2004-07-29 |
AU2003297310A8 (en) | 2004-08-10 |
US20040129134A1 (en) | 2004-07-08 |
WO2004063603A3 (en) | 2005-04-07 |
US6973723B2 (en) | 2005-12-13 |
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Legal Events
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AS | Assignment |
Owner name: INTERNATIONAL ENGINE INTELLECTUAL PROPERTY COMPANY Free format text: ASSIGNMENT OF ASSIGNORS INTEREST;ASSIGNORS:CAGNEY, JOHN L.;PETROV, VALERI B.;REEL/FRAME:017850/0936 Effective date: 20021220 |
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STCB | Information on status: application discontinuation |
Free format text: ABANDONED -- FAILURE TO RESPOND TO AN OFFICE ACTION |