US3919755A - Method of making a high-strength heat-insulating casting - Google Patents

Method of making a high-strength heat-insulating casting Download PDF

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Publication number
US3919755A
US3919755A US41145973A US3919755A US 3919755 A US3919755 A US 3919755A US 41145973 A US41145973 A US 41145973A US 3919755 A US3919755 A US 3919755A
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US
United States
Prior art keywords
casting
heat
liner
ceramic
flexible
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.)
Expired - Lifetime
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English (en)
Inventor
Yasuhisa Kaneko
Yasuhiko Komatsu
Yasuo Okada
Ryuichi Masuda
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Toyota Motor Corp
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Toyota Motor Corp
Priority date (The priority date 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 date listed.)
Filing date
Publication date
Application filed by Toyota Motor Corp filed Critical Toyota Motor Corp
Application granted granted Critical
Publication of US3919755A publication Critical patent/US3919755A/en
Anticipated expiration legal-status Critical
Expired - Lifetime legal-status Critical Current

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    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL-COMBUSTION ENGINES
    • F01N13/00—Exhaust or silencing apparatus characterised by constructional features
    • F01N13/14—Exhaust or silencing apparatus characterised by constructional features having thermal insulation
    • 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
    • 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
    • F02F1/00—Cylinders; Cylinder heads 
    • F02F1/24—Cylinder heads
    • F02F1/26—Cylinder heads having cooling means
    • F02F1/36—Cylinder heads having cooling means for liquid cooling
    • F02F1/38—Cylinder heads having cooling means for liquid cooling the cylinder heads being of overhead valve type
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL-COMBUSTION ENGINES
    • F01N2310/00—Selection of sound absorbing or insulating material
    • F01N2310/06—Porous ceramics
    • 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
    • F02B1/00—Engines characterised by fuel-air mixture compression
    • F02B1/02—Engines characterised by fuel-air mixture compression with positive ignition
    • F02B1/04—Engines characterised by fuel-air mixture compression with positive ignition with fuel-air mixture admission into cylinder
    • 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
    • Y10T29/4927—Cylinder, cylinder head or engine valve sleeve making
    • Y10T29/49272—Cylinder, cylinder head or engine valve sleeve making with liner, coating, or sleeve
    • 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
    • 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
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/249921—Web or sheet containing structurally defined element or component
    • Y10T428/249953—Composite having voids in a component [e.g., porous, cellular, etc.]
    • Y10T428/249967—Inorganic matrix in void-containing component
    • Y10T428/24997—Of metal-containing material

Definitions

  • a flexible ceramic material whose particles are loosely bonded is especially liable to fly apart and unable to stand long hours of service.
  • the high-strength heat-insulating casting according to the present invention when used in an automotive exhaust system, serves to keep the exhaust gas hot, thereby reburning it and consequently reducing the harmful auto emissions.
  • FIG. I is a sectional view taken through a cylinder head made of a high-strength heat-insulating casting as described in Example I of the present invention.
  • FIG. 2 is a sectional view taken through a largecapacity manifold made from a high-strength heatinsulating casting as described in Example 2 of the present invention.
  • reference numeral 1 indicates the port liner
  • reference numerals 2 and 3 indicate ceramic pipes.
  • the present invention relates to a high-strength heatinsulating casting consisting of a flexible ceramic molded liner onto which a metallic article has been cast from molten metal, after which the liner is impregnated with a heat-resistant binder.
  • Heat-resistant binders suitable for this purpose include: sodium silicate, colloidal silica, primary aluminum phosphate, ethyl silicate, etc.
  • a recommended flexible ceramic suitable for this purpose is a refractory aggregate of alumina, silica, cordierite or magnesia which has been mixed with an adequate amount of alumina cement and then fired to an extent such that the aggregate particles are not perfectly sintered together.
  • the molten metal may be gray cast iron, spherical graphite cast iron, an aluminum alloy or cast steel, but any casting metal will do.
  • EXAMPLE 1 This example relates to the use of the high-strength heat-insulating casting according to the present invention as the material for the port liner of an aluminum alloy cylinder head in a 1600 cc four-cylinder gasoline engine.
  • a sectional view of the cylinder head is shown in FIG. 1.
  • a ceramic port liner 1 (wall thickness 4mm), as shown in the figure, was impregnated with sodium silicate as the heat-resistant binder.
  • This port liner 1 had been manufactured by adding 22 parts of water to 100 parts of a mixture of 75 parts of alumina aggregate (maximum grain size 2.5mm) and 25 parts of alumina cement (parts are invariably parts by weight) and casting a slurry obtained by stirring these constituents.
  • This ceramic port liner was set in a casting mold to produce a cylinder head by low pressure casting. After casting, the core sands in the exhaust port were removed and then 100 parts by volume of sodium silicate JIS No. 3 added with 30 parts of water was applied to the port liner with a brush.
  • This silicate J IS No. 3 consists of 2830% of SiOZ, 940% of Na O and the balance of water, its viscosity being over 40 at 15C by means of a Baume hydrometer. After perfect penetration of the sodium silicate, the liner was heated for three hours at 200C.
  • the cylinder head thus produced was assembled into an automobile, which was subjected to an endurance test for 400 hours at 600 rpm under full load without developing any defects.
  • EXAMPLE 2 In this example the high-strength heat-insulating casting according to the present invention is used in a large-capacity manifold in a 2000 cc six-cylinder gasoline engine.
  • FIG. 2 A sectional view of said manifold is shown in FIG. 2, the ceramic pipes 2 and 3 of which (having a wall thickness of 5mm) were impregnated with colloidal silica as the heat-insulating binder.
  • These pipes 2 and 3 were produced by adding 18 parts of water to 100 parts of a mixture containing 80 parts of molten silica aggregate (maximum grain size 1.5mm) and 20 parts of alumina cement and casting the slurry obtained by stirring them together.
  • the large-capacity manifold thus produced was installed in an engine, which 4 was subjected to hours of cold-hot cycle testing (one cycle being 10 minutes of running at an exhaust gas temperature of 950C, immediately followed by 5 minutes of running at an exhaust gas temperature of C), but no undesirable effects resulted.
  • Method of manufacturing a high-strength, heatinsulating casting which comprises the steps of molding a flexible porous ceramic liner from a mixture of a refractory material and alumina cement, which mixture is substantially free from any heatresistant binder,
  • refractory material is selected from the group consisting of alumina, silica, cordierite and magnesia.
  • thermoplastic binder is selected from the group consisting of sodium silica, colloidal silica, primary aluminum phosphate and ethyl silicate.

Landscapes

  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Combustion & Propulsion (AREA)
  • General Engineering & Computer Science (AREA)
  • Exhaust Silencers (AREA)
  • Exhaust Gas After Treatment (AREA)
  • Laminated Bodies (AREA)
  • Ceramic Products (AREA)
  • Cylinder Crankcases Of Internal Combustion Engines (AREA)
US41145973 1973-03-06 1973-10-31 Method of making a high-strength heat-insulating casting Expired - Lifetime US3919755A (en)

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
JP2638673A JPS5248602B2 (enrdf_load_stackoverflow) 1973-03-06 1973-03-06

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US3919755A true US3919755A (en) 1975-11-18

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JP (1) JPS5248602B2 (enrdf_load_stackoverflow)

Cited By (29)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3987143A (en) * 1975-06-05 1976-10-19 Chrysler Corporation Method of decreasing heat loss from exhaust gases of an internal combustion engine
US4346556A (en) * 1980-05-12 1982-08-31 General Motors Corporation Insulating engine exhaust port liner
US4376374A (en) * 1977-11-16 1983-03-15 Repwell Associates, Inc. Metal-ceramic composite and method for making same
US4398527A (en) * 1980-08-22 1983-08-16 Chevron Research Company Internal combustion engine having manifold and combustion surfaces coated with a foam
US4401729A (en) * 1978-05-17 1983-08-30 Nils Claussen High-strength ceramic laminated tube and the production and use thereof
US4530864A (en) * 1983-09-02 1985-07-23 Toshiba Ceramics Co., Ltd. Porous ceramic structure
US4533579A (en) * 1974-03-23 1985-08-06 Toyoda Jidosha Kogyo Kabushiki Kaisha Vibration-resistant, heat-insulating casting and method of making
US4552252A (en) * 1979-09-06 1985-11-12 Kurt Stahl Carrier body for a disc brake pad
DE3536804A1 (de) * 1985-10-16 1987-04-16 Audi Ag Abblaseventil
US4676064A (en) * 1984-04-24 1987-06-30 Ngk Spark Plug Co., Ltd. Heat-insulated port liner arrangement and method of fabrication
WO1989003930A1 (en) * 1987-10-23 1989-05-05 Adiabatics, Inc. Thin thermal barrier coating for engines
US4849266A (en) * 1987-11-03 1989-07-18 Lanxide Technology Company, Lp Compliant layer
US4873952A (en) * 1987-03-02 1989-10-17 Ngk Spark Plug Co., Ltd. Engine cylinder head with precombustion chambers using porous ceramics insert
US4890663A (en) * 1987-05-21 1990-01-02 Interatom Gmbh Method for producing a ceramic-coated metallic component
US4899707A (en) * 1987-02-23 1990-02-13 Ngk Spark Plug Company, Limited Engine cylinder head with precombustion chambers using ceramics insert
US4908923A (en) * 1988-10-05 1990-03-20 Ford Motor Company Method of dimensionally stabilizing interface between dissimilar metals in an internal combustion engine
US4942915A (en) * 1987-08-29 1990-07-24 Eisengiesserei Monforts Gmbh & Co. Process for production of a hollow casting
US4956319A (en) * 1987-11-03 1990-09-11 Lanxide Technology Company, Lp Compliant layer
US4972674A (en) * 1988-05-02 1990-11-27 Ngk Insulators, Ltd. Heat insulating ceramic insert-cast articles for use in exhaust channels in internal combustion engines and a process for producing the same
EP0352246A3 (en) * 1988-07-21 1990-12-27 Eka Nobel Aktiebolag Ceramic coating on metal
US5020319A (en) * 1987-06-09 1991-06-04 Ngk Spark Plug Co., Ltd. Hollow heat-resisting body assembly for internal combustion engine
US5137789A (en) * 1990-12-03 1992-08-11 Caterpillar Inc. Composite ceramic and metal article
US5239956A (en) * 1991-06-07 1993-08-31 Detroit Diesel Corporation Internal combustion engine cylinder heads and similar articles of manufacture and methods of manufacturing same
US5251683A (en) * 1991-03-11 1993-10-12 General Motors Corporation Method of making a cylinder head or other article with cast in-situ ceramic tubes
US5552196A (en) * 1994-02-24 1996-09-03 Caterpillar Inc. Insulated port linear assembly
US6105235A (en) * 1994-04-28 2000-08-22 Johnson & Johnson Professional, Inc. Ceramic/metallic articulation component and prosthesis
US20050035501A1 (en) * 2003-05-12 2005-02-17 Ishikawajima-Harima Heavy Industries Co., Ltd. Heat-resistant ceramic core with three-dimentional shape and method of manufacturing cast by the same
US20150211383A1 (en) * 2014-01-27 2015-07-30 Ford Global Technologies, Llc Internal combustion engine with cooled turbine
US9790836B2 (en) 2012-11-20 2017-10-17 Tenneco Automotive Operating Company, Inc. Loose-fill insulation exhaust gas treatment device and methods of manufacturing

Families Citing this family (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPS5171425U (enrdf_load_stackoverflow) * 1974-12-02 1976-06-05
JPS5287815U (enrdf_load_stackoverflow) * 1975-12-25 1977-06-30
JPS5322947U (enrdf_load_stackoverflow) * 1976-08-04 1978-02-25

Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3173451A (en) * 1960-06-23 1965-03-16 Owens Corning Fiberglass Corp Cast manifold with liner
US3279443A (en) * 1963-11-08 1966-10-18 Morganite Carbon Ltd Cylinder liners
US3568723A (en) * 1967-06-23 1971-03-09 Du Pont Metal-ceramic composite structures
US3714971A (en) * 1971-01-25 1973-02-06 Phillips Petroleum Co High temperature refractory lining
US3786795A (en) * 1971-11-30 1974-01-22 Toyota Motor Co Ltd Cylinder head
US3832273A (en) * 1972-05-15 1974-08-27 Carborundum Co Composite refractory articles

Patent Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3173451A (en) * 1960-06-23 1965-03-16 Owens Corning Fiberglass Corp Cast manifold with liner
US3279443A (en) * 1963-11-08 1966-10-18 Morganite Carbon Ltd Cylinder liners
US3568723A (en) * 1967-06-23 1971-03-09 Du Pont Metal-ceramic composite structures
US3714971A (en) * 1971-01-25 1973-02-06 Phillips Petroleum Co High temperature refractory lining
US3786795A (en) * 1971-11-30 1974-01-22 Toyota Motor Co Ltd Cylinder head
US3832273A (en) * 1972-05-15 1974-08-27 Carborundum Co Composite refractory articles

Cited By (34)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4533579A (en) * 1974-03-23 1985-08-06 Toyoda Jidosha Kogyo Kabushiki Kaisha Vibration-resistant, heat-insulating casting and method of making
US3987143A (en) * 1975-06-05 1976-10-19 Chrysler Corporation Method of decreasing heat loss from exhaust gases of an internal combustion engine
US4376374A (en) * 1977-11-16 1983-03-15 Repwell Associates, Inc. Metal-ceramic composite and method for making same
US4401729A (en) * 1978-05-17 1983-08-30 Nils Claussen High-strength ceramic laminated tube and the production and use thereof
US4552252A (en) * 1979-09-06 1985-11-12 Kurt Stahl Carrier body for a disc brake pad
US4346556A (en) * 1980-05-12 1982-08-31 General Motors Corporation Insulating engine exhaust port liner
US4398527A (en) * 1980-08-22 1983-08-16 Chevron Research Company Internal combustion engine having manifold and combustion surfaces coated with a foam
US4530864A (en) * 1983-09-02 1985-07-23 Toshiba Ceramics Co., Ltd. Porous ceramic structure
US4676064A (en) * 1984-04-24 1987-06-30 Ngk Spark Plug Co., Ltd. Heat-insulated port liner arrangement and method of fabrication
DE3536804A1 (de) * 1985-10-16 1987-04-16 Audi Ag Abblaseventil
US4899707A (en) * 1987-02-23 1990-02-13 Ngk Spark Plug Company, Limited Engine cylinder head with precombustion chambers using ceramics insert
US4873952A (en) * 1987-03-02 1989-10-17 Ngk Spark Plug Co., Ltd. Engine cylinder head with precombustion chambers using porous ceramics insert
US4890663A (en) * 1987-05-21 1990-01-02 Interatom Gmbh Method for producing a ceramic-coated metallic component
US5020319A (en) * 1987-06-09 1991-06-04 Ngk Spark Plug Co., Ltd. Hollow heat-resisting body assembly for internal combustion engine
US4942915A (en) * 1987-08-29 1990-07-24 Eisengiesserei Monforts Gmbh & Co. Process for production of a hollow casting
US4852542A (en) * 1987-10-23 1989-08-01 Adiabatics, Inc. Thin thermal barrier coating for engines
WO1989003930A1 (en) * 1987-10-23 1989-05-05 Adiabatics, Inc. Thin thermal barrier coating for engines
US4849266A (en) * 1987-11-03 1989-07-18 Lanxide Technology Company, Lp Compliant layer
US4956319A (en) * 1987-11-03 1990-09-11 Lanxide Technology Company, Lp Compliant layer
US4972674A (en) * 1988-05-02 1990-11-27 Ngk Insulators, Ltd. Heat insulating ceramic insert-cast articles for use in exhaust channels in internal combustion engines and a process for producing the same
EP0352246A3 (en) * 1988-07-21 1990-12-27 Eka Nobel Aktiebolag Ceramic coating on metal
US4908923A (en) * 1988-10-05 1990-03-20 Ford Motor Company Method of dimensionally stabilizing interface between dissimilar metals in an internal combustion engine
US5137789A (en) * 1990-12-03 1992-08-11 Caterpillar Inc. Composite ceramic and metal article
US5251683A (en) * 1991-03-11 1993-10-12 General Motors Corporation Method of making a cylinder head or other article with cast in-situ ceramic tubes
US5239956A (en) * 1991-06-07 1993-08-31 Detroit Diesel Corporation Internal combustion engine cylinder heads and similar articles of manufacture and methods of manufacturing same
US5354608A (en) * 1991-06-07 1994-10-11 Detroit Diesel Corporation Internal combustion engine cylinder heads and similar articles of manufacture and methods of manufacturing same
US5705266A (en) * 1991-06-07 1998-01-06 Detroit Diesel Corporation Core material for the casting of articles and related process
US5552196A (en) * 1994-02-24 1996-09-03 Caterpillar Inc. Insulated port linear assembly
US5593745A (en) * 1994-02-24 1997-01-14 Caterpillar Inc. Insulated port liner assembly
US6105235A (en) * 1994-04-28 2000-08-22 Johnson & Johnson Professional, Inc. Ceramic/metallic articulation component and prosthesis
US20050035501A1 (en) * 2003-05-12 2005-02-17 Ishikawajima-Harima Heavy Industries Co., Ltd. Heat-resistant ceramic core with three-dimentional shape and method of manufacturing cast by the same
US9790836B2 (en) 2012-11-20 2017-10-17 Tenneco Automotive Operating Company, Inc. Loose-fill insulation exhaust gas treatment device and methods of manufacturing
US20150211383A1 (en) * 2014-01-27 2015-07-30 Ford Global Technologies, Llc Internal combustion engine with cooled turbine
US9784127B2 (en) * 2014-01-27 2017-10-10 Ford Global Technologies, Llc Internal combustion engine with cooled turbine

Also Published As

Publication number Publication date
JPS49114607A (enrdf_load_stackoverflow) 1974-11-01
JPS5248602B2 (enrdf_load_stackoverflow) 1977-12-10

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