US20220010415A1 - Material Composition For A Coating For Components Of Internal Combustion Engines - Google Patents
Material Composition For A Coating For Components Of Internal Combustion Engines Download PDFInfo
- Publication number
- US20220010415A1 US20220010415A1 US17/295,220 US201917295220A US2022010415A1 US 20220010415 A1 US20220010415 A1 US 20220010415A1 US 201917295220 A US201917295220 A US 201917295220A US 2022010415 A1 US2022010415 A1 US 2022010415A1
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- US
- United States
- Prior art keywords
- coating
- wire
- internal combustion
- component
- plasma
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Abandoned
Links
- 238000000576 coating method Methods 0.000 title claims abstract description 28
- 239000011248 coating agent Substances 0.000 title claims abstract description 27
- 239000000203 mixture Substances 0.000 title claims abstract description 27
- 239000000463 material Substances 0.000 title claims abstract description 25
- 238000002485 combustion reaction Methods 0.000 title claims abstract description 20
- 238000000034 method Methods 0.000 claims description 38
- 229910052751 metal Inorganic materials 0.000 claims description 17
- 239000002184 metal Substances 0.000 claims description 17
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 claims description 12
- 239000007921 spray Substances 0.000 claims description 12
- 238000005266 casting Methods 0.000 claims description 8
- 229910052799 carbon Inorganic materials 0.000 claims description 7
- 229910052804 chromium Inorganic materials 0.000 claims description 7
- 239000011651 chromium Substances 0.000 claims description 7
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 claims description 6
- 229910052742 iron Inorganic materials 0.000 claims description 6
- 229910000838 Al alloy Inorganic materials 0.000 claims description 5
- VYZAMTAEIAYCRO-UHFFFAOYSA-N Chromium Chemical compound [Cr] VYZAMTAEIAYCRO-UHFFFAOYSA-N 0.000 claims description 5
- 229910052796 boron Inorganic materials 0.000 claims description 4
- 238000007749 high velocity oxygen fuel spraying Methods 0.000 claims description 3
- 229940098458 powder spray Drugs 0.000 claims description 3
- 229910052710 silicon Inorganic materials 0.000 claims description 2
- ZOXJGFHDIHLPTG-UHFFFAOYSA-N Boron Chemical compound [B] ZOXJGFHDIHLPTG-UHFFFAOYSA-N 0.000 claims 3
- 239000008199 coating composition Substances 0.000 claims 3
- WPBNNNQJVZRUHP-UHFFFAOYSA-L manganese(2+);methyl n-[[2-(methoxycarbonylcarbamothioylamino)phenyl]carbamothioyl]carbamate;n-[2-(sulfidocarbothioylamino)ethyl]carbamodithioate Chemical compound [Mn+2].[S-]C(=S)NCCNC([S-])=S.COC(=O)NC(=S)NC1=CC=CC=C1NC(=S)NC(=O)OC WPBNNNQJVZRUHP-UHFFFAOYSA-L 0.000 claims 3
- 239000010703 silicon Substances 0.000 claims 1
- 239000007789 gas Substances 0.000 description 11
- 238000005260 corrosion Methods 0.000 description 4
- 230000007797 corrosion Effects 0.000 description 4
- 238000000889 atomisation Methods 0.000 description 3
- 239000000446 fuel Substances 0.000 description 3
- 238000002844 melting Methods 0.000 description 3
- 230000008018 melting Effects 0.000 description 3
- 239000007787 solid Substances 0.000 description 3
- XKRFYHLGVUSROY-UHFFFAOYSA-N Argon Chemical compound [Ar] XKRFYHLGVUSROY-UHFFFAOYSA-N 0.000 description 2
- 229910052782 aluminium Inorganic materials 0.000 description 2
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 description 2
- 230000000694 effects Effects 0.000 description 2
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 description 1
- 229910001060 Gray iron Inorganic materials 0.000 description 1
- UFHFLCQGNIYNRP-UHFFFAOYSA-N Hydrogen Chemical compound [H][H] UFHFLCQGNIYNRP-UHFFFAOYSA-N 0.000 description 1
- ZOKXTWBITQBERF-UHFFFAOYSA-N Molybdenum Chemical compound [Mo] ZOKXTWBITQBERF-UHFFFAOYSA-N 0.000 description 1
- 230000001133 acceleration Effects 0.000 description 1
- 239000000654 additive Substances 0.000 description 1
- 230000000996 additive effect Effects 0.000 description 1
- 229910052786 argon Inorganic materials 0.000 description 1
- 229910052802 copper Inorganic materials 0.000 description 1
- 239000010949 copper Substances 0.000 description 1
- 239000001257 hydrogen Substances 0.000 description 1
- 229910052739 hydrogen Inorganic materials 0.000 description 1
- 229910052750 molybdenum Inorganic materials 0.000 description 1
- 239000011733 molybdenum Substances 0.000 description 1
- 230000008092 positive effect Effects 0.000 description 1
- 239000000843 powder Substances 0.000 description 1
- 238000005507 spraying Methods 0.000 description 1
- 239000010935 stainless steel Substances 0.000 description 1
- 229910001220 stainless steel Inorganic materials 0.000 description 1
- WFKWXMTUELFFGS-UHFFFAOYSA-N tungsten Chemical compound [W] WFKWXMTUELFFGS-UHFFFAOYSA-N 0.000 description 1
- 229910052721 tungsten Inorganic materials 0.000 description 1
- 239000010937 tungsten Substances 0.000 description 1
Classifications
-
- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C38/00—Ferrous alloys, e.g. steel alloys
- C22C38/18—Ferrous alloys, e.g. steel alloys containing chromium
- C22C38/38—Ferrous alloys, e.g. steel alloys containing chromium with more than 1.5% by weight of manganese
-
- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C30/00—Coating with metallic material characterised only by the composition of the metallic material, i.e. not characterised by the coating process
-
- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C38/00—Ferrous alloys, e.g. steel alloys
- C22C38/02—Ferrous alloys, e.g. steel alloys containing silicon
-
- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C38/00—Ferrous alloys, e.g. steel alloys
- C22C38/04—Ferrous alloys, e.g. steel alloys containing manganese
-
- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C38/00—Ferrous alloys, e.g. steel alloys
- C22C38/18—Ferrous alloys, e.g. steel alloys containing chromium
- C22C38/32—Ferrous alloys, e.g. steel alloys containing chromium with boron
-
- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C38/00—Ferrous alloys, e.g. steel alloys
- C22C38/18—Ferrous alloys, e.g. steel alloys containing chromium
- C22C38/36—Ferrous alloys, e.g. steel alloys containing chromium with more than 1.7% by weight of carbon
-
- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C28/00—Coating for obtaining at least two superposed coatings either by methods not provided for in a single one of groups C23C2/00 - C23C26/00 or by combinations of methods provided for in subclasses C23C and C25C or C25D
- C23C28/02—Coating for obtaining at least two superposed coatings either by methods not provided for in a single one of groups C23C2/00 - C23C26/00 or by combinations of methods provided for in subclasses C23C and C25C or C25D only coatings only including layers of metallic material
-
- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C28/00—Coating for obtaining at least two superposed coatings either by methods not provided for in a single one of groups C23C2/00 - C23C26/00 or by combinations of methods provided for in subclasses C23C and C25C or C25D
- C23C28/02—Coating for obtaining at least two superposed coatings either by methods not provided for in a single one of groups C23C2/00 - C23C26/00 or by combinations of methods provided for in subclasses C23C and C25C or C25D only coatings only including layers of metallic material
- C23C28/021—Coating for obtaining at least two superposed coatings either by methods not provided for in a single one of groups C23C2/00 - C23C26/00 or by combinations of methods provided for in subclasses C23C and C25C or C25D only coatings only including layers of metallic material including at least one metal alloy layer
-
- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
- C23C4/02—Pretreatment of the material to be coated, e.g. for coating on selected surface areas
-
- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
- C23C4/04—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge characterised by the coating material
- C23C4/06—Metallic material
-
- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
- C23C4/04—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge characterised by the coating material
- C23C4/06—Metallic material
- C23C4/08—Metallic material containing only metal elements
-
- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
- C23C4/12—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge characterised by the method of spraying
- C23C4/129—Flame spraying
-
- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
- C23C4/12—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge characterised by the method of spraying
- C23C4/131—Wire arc spraying
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- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
- C23C4/12—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge characterised by the method of spraying
- C23C4/134—Plasma spraying
Definitions
- the invention relates to a material composition for producing a coating for components of internal combustion engines, in particular for cylinder and/or piston surfaces, according to the features of the preamble of the independent claims.
- FIGURES in the second column of the table above represent preferred values of the component used of the respective composition (that means that for the 1. variants carbon can be selected from the range between 0.1% and 5% carbon, preferably 0.8% carbon. The same applies to the other two variants.
- the 1. variant can also optionally contain 0.1-10% B, the 2. and/or 3. variant can contain independently of one another 0.0-5%, preferably 0.0-1% Si.
- the material composition can have one of the following material compositions:
- the material composition according to the invention can be used as a coating on components of internal combustion engines, in this case in particular, diesel engines.
- Components of internal combustion engines are in particular cylinder running surfaces, pistons, or inlet and outlet channels in the cylinder head.
- the cylinder running surfaces can be honed (i.e. smooth) or roughened before the coating with the material composition according to the invention is applied.
- the chromium content increases the wear resistance and corrosion resistance of the coating.
- the coating according to the invention leads to an improvement in the exhaust gas behavior and to a reduction in fuel consumption.
- the material composition according to the invention is preferably supplied to the coating process in the form of wire. However, other designs are not excluded.
- the coating is preferably applied to the components using the “Plasma Transferred Wire Arc” (PTWA) process, in particular in the form of a wire.
- PTWA Pulsma Transferred Wire Arc
- the material composition which is present as a wire can be applied, for example, using a wire spraying process, for example PTWA with alloyed solid wires or with supplementary wire filled with solids and optional smooth honing, on a component of internal combustion engines (especially cylinder running surfaces).
- a wire spraying process for example PTWA with alloyed solid wires or with supplementary wire filled with solids and optional smooth honing, on a component of internal combustion engines (especially cylinder running surfaces).
- a PTWA internal coating system is suitable for coating cylinder running surfaces.
- a PTWA (Plasma TransferredWire) coating system is a unit for coating bores with a diameter of 65 to 350 mm.
- the spray additive is supplied in the form of a wire.
- the nozzle unit may consist of a thorium-doped tungsten cathode, an air-cooled pilot nozzle made of copper and an electrically conductive wire-shaped supplementary material, which is supplied perpendicularly to the pilot nozzle.
- the plasma gas a mixture of hydrogen and argon, is supplied through bores present in the cathode holder that are tangential to the circumference.
- the position of the cylinder bores creates a gas stream that is twisted along the cathode and escapes through the nozzle at high speed.
- the process is started by a high voltage discharge, which ionizes and dissociates the plasma gas between the pilot nozzle and the cathode.
- the plasma generated in this way flows at high speed through the nozzle orifice and expands along the longitudinal axis of the nozzle.
- the plasma is transported to the supplementary wire material that is continuously supplied perpendicularly to the nozzle, thereby closing the electrical circuit. Melting and atomization of the wire are influenced in two ways. On the one hand, the wire is resistance-heated by high currents, for example 65 to 90 amps. The impact of the plasma on the preheated wire ensures its melting and its atomization.
- Devices for thermal coating a surface are described, for example, in U.S. Pat. No. 6,372,298 B1, U.S. Pat. No. 6,706,993 B1 and WO2010/112567 A1.
- the devices mentioned there have in common: a wire supply device for supplying a wire that is melting off, the wire acting as an electrode; a source of plasma gas for generating a plasma gas flow; a nozzle body with a nozzle opening through which the plasma gas flow is directed onto one end of the wire as a plasma gas jet; and a second electrode arranged in the plasma gas stream before it enters the nozzle opening.
- U.S. Pat. No. 6,610,959 B2 and WO2012/95371 A1 also deal with such devices.
- An arc is formed between the two electrodes through the nozzle opening.
- the plasma jet emerging from the nozzle opening strikes the end of the wire, and, together with the arc, effects the wire to melt off and the molten wire material to be transported in the direction of the surface to be coated.
- Secondary air nozzles are attached in a ring around the nozzle opening, which secondary air nozzles generate a secondary gas jet that hits the material melted off from the wire end and thus effects an acceleration of the transport in the direction of the surface to be coated and secondary atomization of the melted wire material.
- Today's internal combustion engines or their engine blocks can be formed by casting a metal or light metal, such as aluminum, with aluminum blocks in particular having an iron or metal layer on their cylinder bores.
- the coating according to the invention is particularly suitable for components that are formed by casting a metal or light metal.
- this can be components made of an aluminum alloy and that have a metal layer to which then the coating of the material composition according to the invention is applied.
- the components can be formed, for example, by casting an aluminum alloy having an iron layer onto which the coating is applied.
- the metal layer can be thermally sprayed onto the component.
- TWA two-wire arc spray processes
- HVOF spray processes and plasma powder spray processes
- the above-mentioned processes are known as plasma wire spray processes or also as PTWA (Plasma Transferred Wire Arc) as thermal spray processes.
- PTWA Pullasma Transferred Wire Arc
- a coating of the cylinder bores using the plasma wire spray processes, i.e. with the PTWA, is advantageous because a coating can be produced that has a positive effect on a reduced wear factor, on a longer service life of the internal combustion engine with lower oil consumption compared to conventional liners with cast liners made of gray cast iron material.
Abstract
The invention relates to a material composition for a coating for components of internal combustion engines, selected from one of the three material compositions indicated in the following table: formula.CMnCrBSiFe1. variant0.1-5%0.1-3% 0-2%0.0-1%remainder2. variant0.1-5%0.1-3%1-13%0.1-10%remainder3. variant0.1-5%0.1-3%8-30%0.1-10%remainder
Description
- This application is filed pursuant to 35 USC 371 and claims priority benefit to PCT application PCT/EP2019/081762 filed Nov. 19, 2019 which claims priority benefit to German patent application number 102018129167.1 filed Nov. 20, 2018, the entire contents of both applications are incorporated herein by reference.
- The invention relates to a material composition for producing a coating for components of internal combustion engines, in particular for cylinder and/or piston surfaces, according to the features of the preamble of the independent claims.
- This coating for components of internal combustion engines, in particular for cylinder and/or piston surfaces, is suitable, for example, as a corrosion and wear-resistant cylinder surface for low friction in internal combustion engines. This corrosion- and wear-resistant cylinder surface for low friction in internal combustion engines is in turn particularly suitable for use in diesel engines.
- There is a need to reduce the transitional friction for achieving a low fuel consumption and the increase in wear resistance and corrosion resistance to exhaust gas recirculation and bad fuel condensates for diesel engines from Euro 6.
- From the prior art it is known to apply a plasma coating with powder of different chromium, molybdenum and solids content to components for internal combustion engines. Such a plasma coating is applied, for example, to cylinders made of stainless steel.
- It is therefore the object of the invention to provide an improved corrosion and wear-resistant cylinder surface for low friction in internal combustion engines.
- The object is achieved according to the invention by each one of the three material compositions listed in the following table.
-
C Mn Cr B Si Fe 1. variant 0.8% C 0.1-5% 0.1-3% 0-2% 0.0-1% remainder (preferably) 2. variant 9% Cr 0.1-5% 0.1-3% 1-13% 0.1-10% remainder (preferably) 3. variant 18% Cr 0.1-5% 0.1-3% 8-30% 0.1-10% remainder (preferably) - The FIGURES in the second column of the table above represent preferred values of the component used of the respective composition (that means that for the 1. variants carbon can be selected from the range between 0.1% and 5% carbon, preferably 0.8% carbon. The same applies to the other two variants. The 1. variant can also optionally contain 0.1-10% B, the 2. and/or 3. variant can contain independently of one another 0.0-5%, preferably 0.0-1% Si.
- Accordingly, in preferred embodiments, the material composition can have one of the following material compositions:
-
C Mn Cr B Si Fe 1. variant 0.8% 0.1-3% 0-2% optionally 0.1-10% 0.0-1% remainder 2. variant 0.1-5% 0.1-3% 9% 0.1-10% optionally 0.1-5% remainder 3. variant 0.1-5% 0.1-3% 18% 0.1-10% optionally 0.1-5% remainder - The material composition according to the invention can be used as a coating on components of internal combustion engines, in this case in particular, diesel engines. Components of internal combustion engines are in particular cylinder running surfaces, pistons, or inlet and outlet channels in the cylinder head. The cylinder running surfaces can be honed (i.e. smooth) or roughened before the coating with the material composition according to the invention is applied.
- The chromium content increases the wear resistance and corrosion resistance of the coating. The coating according to the invention leads to an improvement in the exhaust gas behavior and to a reduction in fuel consumption.
- The material composition according to the invention is preferably supplied to the coating process in the form of wire. However, other designs are not excluded.
- The coating is preferably applied to the components using the “Plasma Transferred Wire Arc” (PTWA) process, in particular in the form of a wire.
- The material composition which is present as a wire, can be applied, for example, using a wire spraying process, for example PTWA with alloyed solid wires or with supplementary wire filled with solids and optional smooth honing, on a component of internal combustion engines (especially cylinder running surfaces).
- For example, a PTWA internal coating system is suitable for coating cylinder running surfaces. A PTWA (Plasma TransferredWire) coating system is a unit for coating bores with a diameter of 65 to 350 mm. The spray additive is supplied in the form of a wire. The nozzle unit may consist of a thorium-doped tungsten cathode, an air-cooled pilot nozzle made of copper and an electrically conductive wire-shaped supplementary material, which is supplied perpendicularly to the pilot nozzle. The plasma gas, a mixture of hydrogen and argon, is supplied through bores present in the cathode holder that are tangential to the circumference. The position of the cylinder bores creates a gas stream that is twisted along the cathode and escapes through the nozzle at high speed. The process is started by a high voltage discharge, which ionizes and dissociates the plasma gas between the pilot nozzle and the cathode. The plasma generated in this way flows at high speed through the nozzle orifice and expands along the longitudinal axis of the nozzle. The plasma is transported to the supplementary wire material that is continuously supplied perpendicularly to the nozzle, thereby closing the electrical circuit. Melting and atomization of the wire are influenced in two ways. On the one hand, the wire is resistance-heated by high currents, for example 65 to 90 amps. The impact of the plasma on the preheated wire ensures its melting and its atomization.
- Devices for thermal coating a surface are described, for example, in U.S. Pat. No. 6,372,298 B1, U.S. Pat. No. 6,706,993 B1 and WO2010/112567 A1. The devices mentioned there have in common: a wire supply device for supplying a wire that is melting off, the wire acting as an electrode; a source of plasma gas for generating a plasma gas flow; a nozzle body with a nozzle opening through which the plasma gas flow is directed onto one end of the wire as a plasma gas jet; and a second electrode arranged in the plasma gas stream before it enters the nozzle opening. U.S. Pat. No. 6,610,959 B2 and WO2012/95371 A1 also deal with such devices.
- An arc is formed between the two electrodes through the nozzle opening. The plasma jet emerging from the nozzle opening strikes the end of the wire, and, together with the arc, effects the wire to melt off and the molten wire material to be transported in the direction of the surface to be coated. Secondary air nozzles are attached in a ring around the nozzle opening, which secondary air nozzles generate a secondary gas jet that hits the material melted off from the wire end and thus effects an acceleration of the transport in the direction of the surface to be coated and secondary atomization of the melted wire material.
- Today's internal combustion engines or their engine blocks can be formed by casting a metal or light metal, such as aluminum, with aluminum blocks in particular having an iron or metal layer on their cylinder bores.
- The coating according to the invention is particularly suitable for components that are formed by casting a metal or light metal. In particular, this can be components made of an aluminum alloy and that have a metal layer to which then the coating of the material composition according to the invention is applied. The components can be formed, for example, by casting an aluminum alloy having an iron layer onto which the coating is applied.
- The metal layer can be thermally sprayed onto the component. In addition to two-wire arc spray processes (TWA), HVOF spray processes and plasma powder spray processes, the above-mentioned processes are known as plasma wire spray processes or also as PTWA (Plasma Transferred Wire Arc) as thermal spray processes. A coating of the cylinder bores using the plasma wire spray processes, i.e. with the PTWA, is advantageous because a coating can be produced that has a positive effect on a reduced wear factor, on a longer service life of the internal combustion engine with lower oil consumption compared to conventional liners with cast liners made of gray cast iron material.
Claims (18)
1. A material composition for a coating for components of internal combustion engines, selected from one of the two material compositions listed in the following table:
2. The material composition according to claim 1 , characterized by the material composition:
3. The material composition according to claim 1 , characterized by the material composition:
4. (canceled)
5. A method of coating at least one component present in an internal combustion engine, the method comprising the step of:
applying a coating composition to at least one surface of the at least one component of an internal combustion engine, the coating composition selected from the group consisting of:
a. a composition consisting essentially of between 0.1 to 5% carbon, between 0.1 and 3% manganese, between 1 to 13% chromium, between 0.1 and 10% boron and iron;
b. a composition composition consisting essentially of between between 0.1 to 5% carbon, between 0.1 and 3% manganese, between 8 to 30% chromium, between 0.1 and 10% boron and iron;
c. a composition composition consisting essentially of between between 0.1 to 5% carbon, between 0.1 and 3% manganese, between 0 and 2% chromium, between 0.1 and 10% boron, between 0 and 1% silicon and iron
6. The method according to claim 5 , characterized in that the coating composition application step include a “Plasma Transferred Wire Arc” (PTWA) process.
7. The method according to claim 6 , characterized in that the material composition is supplied to the “Plasma Transferred Arc Wire” (PTWA) process in the form of a wire.
8. The method according to claim 5 , characterized in that the components are formed by casting a metal or light metal.
9. The method according to claim 5 , characterized in that the at least one component of the internal combustion engine is formed by casting an aluminum alloy having a metal layer to which the coating is applied.
10. The method according to claim 9 , characterized in that the at least one component of the internal combustion engine is formed by casting an aluminum alloy having an iron layer to which the coating is applied.
11. The method according to claim 9 , characterized in that metal layer is thermally sprayed onto the component.
12. The method according to claim 11 , characterized in that the metal layer is thermally sprayed onto the component by means of a two-wire arc spray process (TWA), HVOF spray process, plasma powder spray process, plasma wire spray process or Plasma Transferred Wire Arc (PTWA) process.
13. The method according to claim 6 characterized in that the coating is applied on the components by means of a “Plasma Transferred Wire Arc” (PTWA) process.
14. The use according to claim 13 , characterized in that the material composition is supplied to the “Plasma Transferred Arc Wire” (PTWA) process in the form of a wire.
15. The method according to claim 14 , characterized in that the at least one component of the internal combustion engine is formed by casting a metal or light metal.
16. The method according to claim 15 , characterized in that the at least one component of the internal combustion engine is formed by casting an aluminum alloy having a metal layer to which the coating is applied.
17. The method according to claim 16 characterized in that metal layer is thermally sprayed onto the component.
18. The method according to claim 11 , characterized in that the metal layer is thermally sprayed onto the component by means of a two-wire arc spray process (TWA), HVOF spray process, plasma powder spray process, plasma wire spray process or Plasma Transferred Wire Arc (PTWA) process.
Applications Claiming Priority (3)
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DE102018129167 | 2018-11-20 | ||
DE102018129167.1 | 2018-11-20 | ||
PCT/EP2019/081762 WO2020104438A1 (en) | 2018-11-20 | 2019-11-19 | Material composition for a coating for components of internal combustion engines |
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US20220010415A1 true US20220010415A1 (en) | 2022-01-13 |
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US17/295,220 Abandoned US20220010415A1 (en) | 2018-11-20 | 2019-11-19 | Material Composition For A Coating For Components Of Internal Combustion Engines |
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US (1) | US20220010415A1 (en) |
CN (1) | CN113454260A (en) |
DE (1) | DE102019131181A1 (en) |
WO (1) | WO2020104438A1 (en) |
Citations (2)
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EP1052435A2 (en) * | 1999-05-14 | 2000-11-15 | Mitsubishi Materials Corporation | Piston ring carrier with cooling cavity and method of manufacturing the same |
KR100593087B1 (en) * | 1998-12-31 | 2006-08-30 | 두산인프라코어 주식회사 | A piston ring for internal combustion engine |
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JP3450727B2 (en) * | 1998-12-11 | 2003-09-29 | 株式会社リケン | Piston ring for internal combustion engine |
US6372298B1 (en) | 2000-07-21 | 2002-04-16 | Ford Global Technologies, Inc. | High deposition rate thermal spray using plasma transferred wire arc |
US6610959B2 (en) | 2001-04-26 | 2003-08-26 | Regents Of The University Of Minnesota | Single-wire arc spray apparatus and methods of using same |
US6706993B1 (en) | 2002-12-19 | 2004-03-16 | Ford Motor Company | Small bore PTWA thermal spraygun |
DE10308563B3 (en) * | 2003-02-27 | 2004-08-19 | Federal-Mogul Burscheid Gmbh | Cylinder lining for engines comprises substrate with wear-resistant coating produced by wire-arc spraying which contains martensitic phases and oxygen |
JP5828575B2 (en) * | 2008-03-04 | 2015-12-09 | 日産自動車株式会社 | piston ring |
EP2236211B1 (en) | 2009-03-31 | 2015-09-09 | Ford-Werke GmbH | Plasma transfer wire arc thermal spray system |
JP5676146B2 (en) * | 2010-05-25 | 2015-02-25 | 株式会社リケン | Pressure ring and manufacturing method thereof |
DE102011002501A1 (en) | 2011-01-11 | 2012-07-12 | Ford-Werke Gmbh | Device for thermally coating a surface |
JP5762843B2 (en) * | 2011-06-22 | 2015-08-12 | 株式会社リケン | Pressure ring and manufacturing method thereof |
CN102618785A (en) * | 2012-02-13 | 2012-08-01 | 新兴铸管股份有限公司 | Cr13 alloy composite coating material of metal pipe, and coating spraying method thereof |
US9475154B2 (en) * | 2013-05-30 | 2016-10-25 | Lincoln Global, Inc. | High boron hardfacing electrode |
BR102014026128B8 (en) * | 2014-10-20 | 2021-08-17 | Mahle Int Gmbh | piston ring and internal combustion engine |
CN105568167B (en) * | 2016-01-14 | 2018-01-12 | 北京工业大学 | A kind of heat-insulated defensive coating material and its coating production |
-
2019
- 2019-11-19 DE DE102019131181.0A patent/DE102019131181A1/en active Pending
- 2019-11-19 US US17/295,220 patent/US20220010415A1/en not_active Abandoned
- 2019-11-19 CN CN201980083523.8A patent/CN113454260A/en active Pending
- 2019-11-19 WO PCT/EP2019/081762 patent/WO2020104438A1/en active Application Filing
Patent Citations (2)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
KR100593087B1 (en) * | 1998-12-31 | 2006-08-30 | 두산인프라코어 주식회사 | A piston ring for internal combustion engine |
EP1052435A2 (en) * | 1999-05-14 | 2000-11-15 | Mitsubishi Materials Corporation | Piston ring carrier with cooling cavity and method of manufacturing the same |
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CN113454260A (en) | 2021-09-28 |
WO2020104438A1 (en) | 2020-05-28 |
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