US3797101A - Method of making die castings having multi-layer coated surfaces - Google Patents

Method of making die castings having multi-layer coated surfaces Download PDF

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Publication number
US3797101A
US3797101A US00309753A US3797101DA US3797101A US 3797101 A US3797101 A US 3797101A US 00309753 A US00309753 A US 00309753A US 3797101D A US3797101D A US 3797101DA US 3797101 A US3797101 A US 3797101A
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United States
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core
metal
coating
layer
casting
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Expired - Lifetime
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US00309753A
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English (en)
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A Bauer
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Farley Inc
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NL Industries Inc
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Assigned to FARLEY METALS, INC. reassignment FARLEY METALS, INC. ASSIGNMENT OF ASSIGNORS INTEREST. Assignors: NL INDUSTRIES, INC. A NJ CORP.
Assigned to NATWEST USA CREDIT CORP. reassignment NATWEST USA CREDIT CORP. SECURITY INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: FARLEY METALS, INC.,
Assigned to FARLEY, INC. reassignment FARLEY, INC. CHANGE OF NAME (SEE DOCUMENT FOR DETAILS). EFFECTIVE DEC. 28, 1987 Assignors: FARLEY METALS, INC.
Assigned to BANK OF NEW YORK, THE reassignment BANK OF NEW YORK, THE SECURITY INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: FARLEY INC.
Assigned to FARLEY, INC. reassignment FARLEY, INC. RELEASED BY SECURED PARTY (SEE DOCUMENT FOR DETAILS). RECORDED AT REEL 4739, FRAME 0041 Assignors: NATWEST USA CREDIT CORP.
Assigned to CONTINENTAL BANK N.A. reassignment CONTINENTAL BANK N.A. SECURITY INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: DOEHLER-JARVIS LIMITED PARTNERSHIP, A DE. LIMITED PARTNERSHIP
Assigned to FARLEY INC. reassignment FARLEY INC. CHANGE OF NAME (SEE DOCUMENT FOR DETAILS). Assignors: FARLEY METALS, INC., A CORP. OF DE.
Assigned to FARLEY INC. reassignment FARLEY INC. RELEASED BY SECURED PARTY (SEE DOCUMENT FOR DETAILS). RELEASE OF SECURED PARTY OF INTEREST RECORDED AT REE 5221 FRAME 038-043 ON JUNE 21, 1989 Assignors: BANK OF NEW YORK, THE
Anticipated expiration legal-status Critical
Assigned to FARLEY INC. reassignment FARLEY INC. CHANGE OF NAME (SEE DOCUMENT FOR DETAILS). EFFECTIVE ON 12/28/1987 Assignors: FARLEY METALS, INC., A CORP. OF DE
Expired - Lifetime legal-status Critical Current

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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D19/00—Casting in, on, or around objects which form part of the product
    • B22D19/0009—Cylinders, pistons
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F02—COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
    • F02B—INTERNAL-COMBUSTION PISTON ENGINES; COMBUSTION ENGINES IN GENERAL
    • F02B53/00—Internal-combustion aspects of rotary-piston or oscillating-piston engines
    • F02B2053/005—Wankel engines
    • 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
    • Y10T29/4998—Combined manufacture including applying or shaping of fluent material
    • Y10T29/49982—Coating
    • Y10T29/49984—Coating and casting
    • 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
    • Y10T29/4998—Combined manufacture including applying or shaping of fluent material
    • Y10T29/49988—Metal casting
    • Y10T29/49989—Followed by cutting or removing material

Definitions

  • the method is particularly directed to the production of a casting having a multiple layer coating wherein the layer exposed to the working surface of the cylinder or housing is of a material which will provide a very hard, wear resistant layer, and the underlayer, between the die casting and the wear resistant layer is of a softer, less expensive, highly adherent and physically strong material.
  • the former process consists of spraying, with a metalizing gun, or otherwise depositing on a cylindrical core portion of a die, a body of metal having a higher melting point than the body of the cylinder or housing of which the casting was to be made. Subsequently, the sprayed or coated core was inserted into a die casting machine and the aluminum or other metal of lower melting point was cast under high pressure around the coated core.
  • the composite or dual layer coating of the present invention has a distinct advantage.
  • the present invention includes a method for producing a coated die casting by depositing a thin layer of very hard material such as tungsten or titanium carbide, on a die casting core, then applying a second, thicker backing layer of metal, such as steel on top of the hard metal layer and adhered thereto by the roughness of the exterior of the deposited hard metal layer.
  • the coated core is then placed in a die casting machine and the cylinder or housing is cast around it as in the previously explained transplant coat process.
  • the coating adheres to the metal of the die casting by interlocking of the casting metal with the rough exterior surface'of the backing layer. The bond between the backing layer and the die casting is extremely good.
  • FIG. 2 is'a view similar to FIG. 1 showing the application of a layer of a second metal backing the first hard layer;
  • FIG. 3 is a diagrammatic view of the core in place in a die casting die, the core bearing both of the previously applied coatings;
  • FIG. 4 is an elevational view of a completed casting with the core removed, leaving the coatings in place in the casting;
  • FIG. 5 is an enlarged, fragmentary sectional view through the wall of the completed casting taken on the line 5-5 of FIG. 4.
  • cylinder and housing indicate cylinders for reciprocating engines and housings for rotary engines inter-changeably.
  • FIG. 1 of the drawings indicates diagrammatically at 10 a core for the manufacture of a housing for a rotary engine.
  • the core 10 is preferably taperfree so as to minimize the machining required to finish the final cast housing.
  • the core 10 is mounted for rotation on a lathe-like machine and a metalizing gun 11 is mounted adjacent the machine to spray a layer 12 of a hard material, such as tungsten carbide, silicon carbide, boron carbide, titanium carbide, chromium carbide or any of several borides, usually associated with a binder such as cobalt, nickel, or the like-
  • the layer 12 can also be of a ceramic material, e.g., zirconia or alumina, which can be applied without a binder, or can be an alloy or a pure metal such as chromium, or molybdenum.
  • the various carbides, borides and the like are generically referred to as hard metal; it is to be understood that this term encompasses the carbide and borides per se as well as in a particulate form dispersed in a binder such as nickel.
  • the layer 12 can be formed by spraying, for example, a Metco 438 or 439 tungsten carbide nickel aluminide blend from the gun 11.
  • the thickness of the hard metal layer 12 is from 0.003 to 0.020 inch, most desirably from 0.005 to 0.015 inch. Thicker coatings are equally operable but for economic reasons the thinnest possible coating requiring the minimum machining is desired.
  • the hard metal layer adheres somewhat to the core but is not bonded thereto.
  • the core 10 may be coated with a solution or dispersion of a release agent such as talc or sodium bicarbonate prior to spraying on the initial hard metal layer.
  • a release agent such as talc or sodium bicarbonate
  • an initial thin separation layer of softer material for example, of a ferrous or non-ferrous metal or alloy, is first deposited on the core.
  • This separation layer can be iron, aluminum, zinc, tin or an alloy thereof and can be applied with a gas or electric metalizing gun.
  • Such a separation layer exhibits much less tendency to adhere to the core than does the hard metal layer.
  • This thin initial separation layer may be only from 0.001 inch to 0.003 inch thick, but it serves as an effective release layer with respect to the core 10.
  • the core having been coated with the hard metal layer 12 as in FIG. 1 is then subjected to spraying from a second gun indicated at 13 which deposits a thicker layer 14 of a material such as steel or a chromium-iron alloy such as is sold under the trade name Metco No. 2.
  • the layer 14 preferably has a thickness from 0.010 to 0.065 inch, most desirably from 0.015 to 0.060 inch.
  • the exterior of the hard metal layer 12 sprayed on as in FIG. 1 is rough and pitted and the steel layer 14 applied as in FIG. 2 from the gun l3 adheres thereto by entering into the interstices of the rough and pitted surface of the exterior of the hard metal layer 12.
  • This coating 14 itself exhibits on its exterior a rough and pitted surface as explained in my prior US. Pat. No. 3,083,424.
  • the gun 13 can be a common gas or electric metalizing gun.
  • the die 16 has a cavity of an appropriate shape surrounding the core 10.
  • the metal of the housing is cast into the cavity of the die 16 under normal die casting pressures which may run from 2000 psi. to 15,000 psi.
  • the high pressure exerted on the casting metal causes this metal to enter into the interstices of the rough, pitted surface of the exterior of the layer 14 of steel or other iron alloy.
  • the completed casting is then permitted to solidify in the die 16 and is subsequently removed with the core 10 still in place.
  • the bond exhibited between the casting metal, which is preferably aluminum, and the coating 14 has a greater strength of adherence than the bond between the initially deposited hard metal layer 12 and the core 10.
  • the coatings 12 and 14 will adhere to the casting and not to the core. Attempts to remove the core from the casting by sheer physical force may result in a destruction of the coating 12 because of the adherence of some of the hard metal particles to the core which would then either score the remainder of the coating or cause its destruction for practical use.
  • FIG. 5 is, of course, an enlarged fragmentary view and shows the relatively thin internal hard metal layer 12 and the relatively thicker backing layer 14 of the iron alloy interlocked to the hard metal layer at the interface 17.
  • the aluminum or casting metal is interlocked as at 18 to the backing layer 14 of the iron alloy.
  • the bond between the layers, at 17 and 18, is only by reason of the interlocking of the material of each layer with its neighboring material in the rough, pitted surface which forms the exterior of the layer after the spray coating application. There appears to be no chemical bonding.
  • the casting is then subjected to a machining operation, usually grinding, to expose the hard metal layer 12 which is desired for the working surface of the housing.
  • the coated casting is then ground to its final finish and dimensions. Even though the hard metal layer may be ground down to a thickness of only a few microns in some areas it will not spall off or crack because the physical strength imparted by the backing layer of iron alloy is such that even though the aluminum of the casting (having a higher coefficient of thermal expansion) tends to expand radially away from the coatings upon heating during engine operation adequate strength of the composite layers is such that cracking does not occur.
  • a method for producing a die casting which comprises applying to a die casting core a relatively thin hard metal coating having a rough and pitted exposed surface, applying to the hard metal coating, and into interlocking engagement with the rough and pitted surface thereof, a relatively thicker backing coating of a metal which is strong, highly adherent, and softer than said hard metal having a rough and pitted exposed surface, positioning the coated core in a die, introducing under die casting pressure a metal having a lower melting temperature than that of either of the coatings into the die and into interlocking engagement with the rough and pitted surface of the metal coating on the core, solidifying the introduced metal, and separating the core from the hard metal layer whereby the interior of the die casting exhibits the hard wear resistant character of the thin initial coating.
  • a method as claimed in claim wherein, after sep-- aration of the core from the casting, the metal coating that was first applied to the core is removed by a machining operation to expose the hard metal coating.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Coating By Spraying Or Casting (AREA)
  • Molds, Cores, And Manufacturing Methods Thereof (AREA)
  • Other Surface Treatments For Metallic Materials (AREA)
US00309753A 1972-11-27 1972-11-27 Method of making die castings having multi-layer coated surfaces Expired - Lifetime US3797101A (en)

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
US30975372A 1972-11-27 1972-11-27

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US3797101A true US3797101A (en) 1974-03-19

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US00309753A Expired - Lifetime US3797101A (en) 1972-11-27 1972-11-27 Method of making die castings having multi-layer coated surfaces

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US (1) US3797101A (ja)
JP (1) JPS5715980B2 (ja)
AR (1) AR208879A1 (ja)
BE (1) BE806081A (ja)
BR (1) BR7304404D0 (ja)
CA (1) CA991378A (ja)
CH (1) CH563819A5 (ja)
DE (1) DE2317937A1 (ja)
FR (1) FR2207769B1 (ja)
GB (1) GB1424419A (ja)
IL (1) IL42985A0 (ja)
IT (1) IT991953B (ja)
NL (1) NL7316248A (ja)
SE (1) SE398452B (ja)
SU (1) SU473339A3 (ja)

Cited By (15)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3860058A (en) * 1973-11-05 1975-01-14 Ford Motor Co Method of forming dimensional holes in the wankel rotor housing electroform
US3864815A (en) * 1973-12-10 1975-02-11 Nl Industries Inc Method of making a lined die casting by employing a transplant coating
US3878880A (en) * 1973-06-25 1975-04-22 Curtiss Wright Corp Composite casting method
US3888296A (en) * 1974-05-30 1975-06-10 Gen Motors Corp Method for the manufacture of a composite article
US3920360A (en) * 1974-05-30 1975-11-18 Gen Motors Corp Aluminum-iron composite rotor housing for a rotary combustion engine and method of making the same
US3921701A (en) * 1973-08-20 1975-11-25 Ford Motor Co Method for improving bond between transplanted coating and die-casting
US3937266A (en) * 1973-08-20 1976-02-10 Ford Motor Company Method for application of wear-resistant coating
US3948309A (en) * 1973-08-20 1976-04-06 Ford Motor Company Composite rotor housing with wear-resistant coating
US5022455A (en) * 1989-07-31 1991-06-11 Sumitomo Electric Industries, Ltd. Method of producing aluminum base alloy containing silicon
US5211153A (en) * 1991-02-01 1993-05-18 Kioritz Corporation Two-cycle internal combustion gasoline engine cylinder
US5855828A (en) * 1994-06-06 1999-01-05 Ultramet Method of forming a composite structure such as a rocket combustion chamber
US6044820A (en) * 1995-07-20 2000-04-04 Spx Corporation Method of providing a cylinder bore liner in an internal combustion engine
US6345439B2 (en) * 1998-11-10 2002-02-12 Kioritz Corp. Method for manufacturing a cylinder for internal combustion engine
US6416072B1 (en) * 1998-08-10 2002-07-09 Honda Giken Kogyo Kabushiki Kaisha Vehicle body frame for motorcycle and it fabrication method
CN102886508A (zh) * 2012-08-27 2013-01-23 吴建化 一种硬质合金或碳化钛与耐磨钢融合的铸造方法

Families Citing this family (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPS60105859U (ja) * 1983-12-23 1985-07-19 本田技研工業株式会社 気化器構成部品の取付け構造
CN107671259A (zh) * 2017-09-29 2018-02-09 安徽金兰压铸有限公司 铝合金结构件弥散强化压铸方法

Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US2074007A (en) * 1934-08-03 1937-03-16 Union Carbide & Carbon Corp Method of making articles of cobaltchromium-tungsten alloys
US3083424A (en) * 1959-05-07 1963-04-02 Nat Lead Co Method for producing coated die castings
US3099869A (en) * 1953-12-02 1963-08-06 Hoover Co Process of bonding metals
US3401736A (en) * 1963-08-27 1968-09-17 Bridgestone Cycle Ind Co Process for formation of non-abrasive refractory rubbing surface having high thermal conductivity by casting
US3433284A (en) * 1966-01-14 1969-03-18 Gen Motors Corp Method of casting a pitted surface
US3689986A (en) * 1967-04-01 1972-09-12 Nippon Piston Ring Co Ltd Method of casting composite cam shafts

Patent Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US2074007A (en) * 1934-08-03 1937-03-16 Union Carbide & Carbon Corp Method of making articles of cobaltchromium-tungsten alloys
US3099869A (en) * 1953-12-02 1963-08-06 Hoover Co Process of bonding metals
US3083424A (en) * 1959-05-07 1963-04-02 Nat Lead Co Method for producing coated die castings
US3401736A (en) * 1963-08-27 1968-09-17 Bridgestone Cycle Ind Co Process for formation of non-abrasive refractory rubbing surface having high thermal conductivity by casting
US3433284A (en) * 1966-01-14 1969-03-18 Gen Motors Corp Method of casting a pitted surface
US3689986A (en) * 1967-04-01 1972-09-12 Nippon Piston Ring Co Ltd Method of casting composite cam shafts

Cited By (16)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3878880A (en) * 1973-06-25 1975-04-22 Curtiss Wright Corp Composite casting method
US3921701A (en) * 1973-08-20 1975-11-25 Ford Motor Co Method for improving bond between transplanted coating and die-casting
US3937266A (en) * 1973-08-20 1976-02-10 Ford Motor Company Method for application of wear-resistant coating
US3948309A (en) * 1973-08-20 1976-04-06 Ford Motor Company Composite rotor housing with wear-resistant coating
US3860058A (en) * 1973-11-05 1975-01-14 Ford Motor Co Method of forming dimensional holes in the wankel rotor housing electroform
US3864815A (en) * 1973-12-10 1975-02-11 Nl Industries Inc Method of making a lined die casting by employing a transplant coating
US3888296A (en) * 1974-05-30 1975-06-10 Gen Motors Corp Method for the manufacture of a composite article
US3920360A (en) * 1974-05-30 1975-11-18 Gen Motors Corp Aluminum-iron composite rotor housing for a rotary combustion engine and method of making the same
US5022455A (en) * 1989-07-31 1991-06-11 Sumitomo Electric Industries, Ltd. Method of producing aluminum base alloy containing silicon
US5211153A (en) * 1991-02-01 1993-05-18 Kioritz Corporation Two-cycle internal combustion gasoline engine cylinder
US5855828A (en) * 1994-06-06 1999-01-05 Ultramet Method of forming a composite structure such as a rocket combustion chamber
US6044820A (en) * 1995-07-20 2000-04-04 Spx Corporation Method of providing a cylinder bore liner in an internal combustion engine
US6416072B1 (en) * 1998-08-10 2002-07-09 Honda Giken Kogyo Kabushiki Kaisha Vehicle body frame for motorcycle and it fabrication method
US6796030B2 (en) 1998-08-10 2004-09-28 Honda Giken Kogyo Kabushiki Kaisha Method of fabricating a vehicle body frame for a motorcycle
US6345439B2 (en) * 1998-11-10 2002-02-12 Kioritz Corp. Method for manufacturing a cylinder for internal combustion engine
CN102886508A (zh) * 2012-08-27 2013-01-23 吴建化 一种硬质合金或碳化钛与耐磨钢融合的铸造方法

Also Published As

Publication number Publication date
BR7304404D0 (pt) 1974-08-22
AR208879A1 (es) 1977-03-15
SE398452B (sv) 1977-12-27
FR2207769A1 (ja) 1974-06-21
NL7316248A (ja) 1974-05-29
AU5620673A (en) 1974-11-28
FR2207769B1 (ja) 1980-04-04
IT991953B (it) 1975-08-30
IL42985A0 (en) 1973-11-28
CH563819A5 (ja) 1975-07-15
JPS5715980B2 (ja) 1982-04-02
SU473339A3 (ru) 1975-06-05
BE806081A (fr) 1974-02-01
CA991378A (en) 1976-06-22
JPS4982529A (ja) 1974-08-08
GB1424419A (en) 1976-02-11
DE2317937A1 (de) 1974-06-06

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