WO2012065674A1 - Lightweight crankdrive and method for manufacturing same - Google Patents

Lightweight crankdrive and method for manufacturing same Download PDF

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Publication number
WO2012065674A1
WO2012065674A1 PCT/EP2011/005307 EP2011005307W WO2012065674A1 WO 2012065674 A1 WO2012065674 A1 WO 2012065674A1 EP 2011005307 W EP2011005307 W EP 2011005307W WO 2012065674 A1 WO2012065674 A1 WO 2012065674A1
Authority
WO
WIPO (PCT)
Prior art keywords
lightweight
connecting rod
crankshaft
crank mechanism
piston pin
Prior art date
Application number
PCT/EP2011/005307
Other languages
German (de)
French (fr)
Inventor
Marco Fandel
Tilmann Haug
Manfred Kurbjuhn
Karl Weisskopf
Original Assignee
Daimler Ag
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 Daimler Ag filed Critical Daimler Ag
Publication of WO2012065674A1 publication Critical patent/WO2012065674A1/en

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Classifications

    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16J—PISTONS; CYLINDERS; SEALINGS
    • F16J1/00—Pistons; Trunk pistons; Plungers
    • F16J1/10—Connection to driving members
    • F16J1/14—Connection to driving members with connecting-rods, i.e. pivotal connections
    • F16J1/16—Connection to driving members with connecting-rods, i.e. pivotal connections with gudgeon-pin; Gudgeon-pins
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B15/00—Layered products comprising a layer of metal
    • B32B15/01—Layered products comprising a layer of metal all layers being exclusively metallic
    • B32B15/012—Layered products comprising a layer of metal all layers being exclusively metallic one layer being formed of an iron alloy or steel, another layer being formed of aluminium or an aluminium alloy
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B15/00—Layered products comprising a layer of metal
    • B32B15/01—Layered products comprising a layer of metal all layers being exclusively metallic
    • B32B15/013—Layered products comprising a layer of metal all layers being exclusively metallic one layer being formed of an iron alloy or steel, another layer being formed of a metal other than iron or aluminium
    • C—CHEMISTRY; METALLURGY
    • C21—METALLURGY OF IRON
    • C21D—MODIFYING THE PHYSICAL STRUCTURE OF FERROUS METALS; GENERAL DEVICES FOR HEAT TREATMENT OF FERROUS OR NON-FERROUS METALS OR ALLOYS; MAKING METAL MALLEABLE, e.g. BY DECARBURISATION OR TEMPERING
    • C21D7/00—Modifying the physical properties of iron or steel by deformation
    • C21D7/13—Modifying the physical properties of iron or steel by deformation by hot working
    • C—CHEMISTRY; METALLURGY
    • C21—METALLURGY OF IRON
    • C21D—MODIFYING THE PHYSICAL STRUCTURE OF FERROUS METALS; GENERAL DEVICES FOR HEAT TREATMENT OF FERROUS OR NON-FERROUS METALS OR ALLOYS; MAKING METAL MALLEABLE, e.g. BY DECARBURISATION OR TEMPERING
    • C21D9/00—Heat treatment, e.g. annealing, hardening, quenching or tempering, adapted for particular articles; Furnaces therefor
    • C21D9/0068—Heat treatment, e.g. annealing, hardening, quenching or tempering, adapted for particular articles; Furnaces therefor for particular articles not mentioned below
    • C—CHEMISTRY; METALLURGY
    • C21—METALLURGY OF IRON
    • C21D—MODIFYING THE PHYSICAL STRUCTURE OF FERROUS METALS; GENERAL DEVICES FOR HEAT TREATMENT OF FERROUS OR NON-FERROUS METALS OR ALLOYS; MAKING METAL MALLEABLE, e.g. BY DECARBURISATION OR TEMPERING
    • C21D9/00—Heat treatment, e.g. annealing, hardening, quenching or tempering, adapted for particular articles; Furnaces therefor
    • C21D9/30—Heat treatment, e.g. annealing, hardening, quenching or tempering, adapted for particular articles; Furnaces therefor for crankshafts; for camshafts
    • 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
    • C22C38/06—Ferrous alloys, e.g. steel alloys containing aluminium
    • 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
    • C22C38/34—Ferrous alloys, e.g. steel alloys containing chromium with more than 1.5% by weight of 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
    • C22C38/18—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
    • 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
    • C23C4/12—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
    • 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
    • C23C4/18—After-treatment
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16C—SHAFTS; FLEXIBLE SHAFTS; ELEMENTS OR CRANKSHAFT MECHANISMS; ROTARY BODIES OTHER THAN GEARING ELEMENTS; BEARINGS
    • F16C3/00—Shafts; Axles; Cranks; Eccentrics
    • F16C3/04—Crankshafts, eccentric-shafts; Cranks, eccentrics
    • F16C3/06—Crankshafts
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16C—SHAFTS; FLEXIBLE SHAFTS; ELEMENTS OR CRANKSHAFT MECHANISMS; ROTARY BODIES OTHER THAN GEARING ELEMENTS; BEARINGS
    • F16C33/00—Parts of bearings; Special methods for making bearings or parts thereof
    • F16C33/02—Parts of sliding-contact bearings
    • F16C33/04—Brasses; Bushes; Linings
    • F16C33/043—Sliding surface consisting mainly of ceramics, cermets or hard carbon, e.g. diamond like carbon [DLC]
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16C—SHAFTS; FLEXIBLE SHAFTS; ELEMENTS OR CRANKSHAFT MECHANISMS; ROTARY BODIES OTHER THAN GEARING ELEMENTS; BEARINGS
    • F16C7/00—Connecting-rods or like links pivoted at both ends; Construction of connecting-rod heads
    • F16C7/02—Constructions of connecting-rods with constant length
    • F16C7/023—Constructions of connecting-rods with constant length for piston engines, pumps or the like
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16C—SHAFTS; FLEXIBLE SHAFTS; ELEMENTS OR CRANKSHAFT MECHANISMS; ROTARY BODIES OTHER THAN GEARING ELEMENTS; BEARINGS
    • F16C9/00—Bearings for crankshafts or connecting-rods; Attachment of connecting-rods
    • F16C9/04—Connecting-rod bearings; Attachments thereof
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16J—PISTONS; CYLINDERS; SEALINGS
    • F16J7/00—Piston-rods
    • C—CHEMISTRY; METALLURGY
    • C21—METALLURGY OF IRON
    • C21D—MODIFYING THE PHYSICAL STRUCTURE OF FERROUS METALS; GENERAL DEVICES FOR HEAT TREATMENT OF FERROUS OR NON-FERROUS METALS OR ALLOYS; MAKING METAL MALLEABLE, e.g. BY DECARBURISATION OR TEMPERING
    • C21D2201/00—Treatment for obtaining particular effects
    • C21D2201/02—Superplasticity
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16C—SHAFTS; FLEXIBLE SHAFTS; ELEMENTS OR CRANKSHAFT MECHANISMS; ROTARY BODIES OTHER THAN GEARING ELEMENTS; BEARINGS
    • F16C2204/00—Metallic materials; Alloys
    • F16C2204/10—Alloys based on copper
    • F16C2204/12—Alloys based on copper with tin as the next major constituent
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16C—SHAFTS; FLEXIBLE SHAFTS; ELEMENTS OR CRANKSHAFT MECHANISMS; ROTARY BODIES OTHER THAN GEARING ELEMENTS; BEARINGS
    • F16C2204/00—Metallic materials; Alloys
    • F16C2204/10—Alloys based on copper
    • F16C2204/14—Alloys based on copper with zinc as the next major constituent
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16C—SHAFTS; FLEXIBLE SHAFTS; ELEMENTS OR CRANKSHAFT MECHANISMS; ROTARY BODIES OTHER THAN GEARING ELEMENTS; BEARINGS
    • F16C2204/00—Metallic materials; Alloys
    • F16C2204/20—Alloys based on aluminium
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16C—SHAFTS; FLEXIBLE SHAFTS; ELEMENTS OR CRANKSHAFT MECHANISMS; ROTARY BODIES OTHER THAN GEARING ELEMENTS; BEARINGS
    • F16C2204/00—Metallic materials; Alloys
    • F16C2204/60—Ferrous alloys, e.g. steel alloys
    • F16C2204/66—High carbon steel, i.e. carbon content above 0.8 wt%, e.g. through-hardenable steel
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16C—SHAFTS; FLEXIBLE SHAFTS; ELEMENTS OR CRANKSHAFT MECHANISMS; ROTARY BODIES OTHER THAN GEARING ELEMENTS; BEARINGS
    • F16C2206/00—Materials with ceramics, cermets, hard carbon or similar non-metallic hard materials as main constituents
    • F16C2206/02—Carbon based material
    • F16C2206/04—Diamond like carbon [DLC]
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16C—SHAFTS; FLEXIBLE SHAFTS; ELEMENTS OR CRANKSHAFT MECHANISMS; ROTARY BODIES OTHER THAN GEARING ELEMENTS; BEARINGS
    • F16C2223/00—Surface treatments; Hardening; Coating
    • F16C2223/10—Hardening, e.g. carburizing, carbo-nitriding
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16C—SHAFTS; FLEXIBLE SHAFTS; ELEMENTS OR CRANKSHAFT MECHANISMS; ROTARY BODIES OTHER THAN GEARING ELEMENTS; BEARINGS
    • F16C2223/00—Surface treatments; Hardening; Coating
    • F16C2223/30—Coating surfaces
    • F16C2223/42—Coating surfaces by spraying the coating material, e.g. plasma spraying

Definitions

  • the invention relates to a lightweight crank mechanism with components made of ultra high carbon lightweight steel for an internal combustion engine, and a method for its production.
  • the weight of combustion engines generally also depends on the stroke volume. Depending on the engine concept and cylinder arrangement, however, there is a large spread of engine weight for the same displacement, depending on the structural and material characteristics of the components.
  • crankshaft Conventionally, for the production of the crankshaft drive components crankshaft, connecting rod and piston pin about classic steel materials used, for example, the steel C70 for the crankshaft, and thus heavy materials.
  • UHC ultra high carbon
  • DE 10 2006 041 902 A1 describes a UHC lightweight structural steel with improved scale resistance, the composition of which comprises from 1 to 1, 6% by weight C, 5 to 10% by weight Al, 0.5 to 3% by weight Cr and 0.1 to 2.8 wt .-% Si and the remainder iron and common steel-accompanying impurities is characterized.
  • the steel composition disclosed therein does not refer to specific components.
  • DE 10 2008 032 024 A1 also discloses a density-reduced UHC lightweight structural steel whose composition contains 0.7 to 1, 6% by weight C, 5 to 12% by weight Al, 0 to 0.4% by weight Cr and 0.01 to 2.8 wt .-% Si and stabilizing alloying elements below 1 wt .-% and the balance iron and common steel-accompanying impurities.
  • suspension components, gear parts, gears or engine components for motor vehicles made of UHC lightweight steel. From the cited prior art it is known that UHC steels can have superplastic properties due to their relatively high carbon content after suitable thermal and mechanical pretreatment. In the case of forming in the superplastic region, which begins at about 600 ° C.
  • the object is to provide a lightweight crank mechanism, which provides by reducing the moving masses an improved friction behavior and thereby also increased agility of the engine.
  • the components of the lightweight crank mechanism according to the invention are obtained from density-reduced ultra-high carbon-containing lightweight steel, which is advantageous for reducing the weight of the crank mechanism.
  • the lightweight crank mechanism consists of crankshaft, connecting rod with large and small connecting rod and piston pin, the crankshaft is mounted in the large connecting rod and the piston pin in the small connecting rod.
  • the crankshaft bearing is formed in the large connecting rod by one or more thermal spray coatings, so that the waiver of a bearing shell also contributes to weight savings.
  • the piston pin of the lightweight crank mechanism according to the invention is equipped with a hard coating, so that even in the small connecting rod eye weight-reducing can be dispensed with a bearing shell.
  • the weight of the crank drive can be reduced by about 11% in a V6 gasoline engine, so that can be saved on this type of engine, for example, up to 3.8 kg.
  • the reduction of the moving masses of the crank mechanism leads to less friction, which manifests itself in an increase in the agility of the engine.
  • a suitable composition of a reduced-density UHC lightweight steel, from which the crankshaft components, crankshaft, connecting rod and piston pin according to the invention consist comprises from 0.7 to 2.0 wt .-% C; 5.0 to 12.0% by weight of Al; 0.01 to 2.8% by weight of Si; 0 to 2.0 wt% Cr; 1, 0 to 5.0 wt .-% Mn and Fe to compensate for the 100 wt .-%. Furthermore, steel-typical contamination traces may be included.
  • the high proportion of aluminum (AI) contributes to the reduction in density, so that the lightweight structural steel according to the invention can be advantageously used just for the production of lightweight components in the automotive industry.
  • the high Al content increases the Ai transformation temperature and thus the maximum superplastic processing temperature. This is further enhanced by a small increase in the silicon (Si) content, with silicon additionally contributing to the reduction in density, but here the deterioration of the mechanical properties must be taken into account by alloying Si.
  • an optimum Ai transformation temperature which allows high deformation rates without changes or damage to the structure, can be set.
  • the formation of scale at the elevated temperatures of the hot working is reduced, which is also supported by the Si content.
  • the brittleness of the reduced density UHC lightweight steel with the high Al content of up to 10% by weight is reduced or its ductility increased, so that during hot forming such as forging or rolling hardly any surface cracks occur and a steel blank made in this way can be directed at room temperature to remedy any distortions.
  • This density-reduced UHC lightweight structural composition has a stable superplastic texture, with mechanical properties improved in ductility for good hot and cold workability, with little or no contribution to expensive alloying elements such as Ni, Mo, V and / or Sn on. Even the low proportion of Cr - under certain circumstances can be dispensed with chrome - has a cost-reducing effect.
  • the increased manganese (Mn) content prevents the deterioration of the mechanical properties at room temperature, which is normally caused by the addition of Si, and which has a strongly embrittling effect.
  • the manganese content also helps to inhibit unwanted graphitization, which is favored due to the high content of Al and Si.
  • the structural state of a UHC steel after its metallurgical production usually does not allow a high forming rate during hot forming. This requires a structure with superplastic properties.
  • superplastic forming operations are less economical compared to hot forming processes, and deviation from the optimal superplastic structure is acceptable when a homogeneous, fine grained, spheroidal carbide distribution is present in a fine-grained ferrite matrix as well, with both carbide and ferrite phases being stable to grain growth and graphitization.
  • Exemplary particle sizes of the microstructure are below 10 ⁇ m, for example with an average particle size of less than 1.5 ⁇ m.
  • a predominant grain content is spheroidal, a low lamellar carbide content does not adversely affect the properties of the UHC steel.
  • the desired phase formation of the microstructure with fine crystallites or grains can be achieved by means of a suitable thermo-mechanical treatment.
  • the UHC lightweight steel has good elongation at break and strength values even at room temperature, the structure with the predominantly spheroidal phases shows little or no crack formation during cold forming.
  • a further suitable composition of the UHC lightweight steel consists of 1, 0 to 1, 6 wt .-% C; 7.0 to 10.0% by weight of Al; 0.01 to 0.6% by weight of Si; 0 to 1, 5 wt .-% Cr; From 2.0 to 3.0% by weight of Mn and to the proportion of Fe equal to 100% by weight and, if appropriate, with the steel-typical traces of contamination.
  • traces of contamination may be, for example, Ni, Mo, Nb, V and / or Cu. As a rule, their proportions are less than 1 wt .-%.
  • crank mechanism with the components made of UHC steel crankshaft, connecting rod and piston pin meets high thermal and mechanical demands and contributes to the lightweight construction to reduce fuel consumption.
  • UHC lightweight steels can also be used as the material for the components, as described in the prior art, to form the crank drive according to the invention with a thermally sprayed crankshaft bearing and a hard-coated piston pin.
  • the piston pin which connects the piston to the connecting rod, can be mounted floating in the small connecting rod eye with very little play.
  • the piston pin is surrounded by the hard material coating.
  • the hard-material coating can be conventional hard-layer materials such as hard metal, metal carbide, ceramic or in particular amorphous, diamond-like carbon (DLC).
  • the thermal spray coating used as a replacement for a bearing shell in the large connecting rod eye, which forms the crankshaft bearing may be a sprayed coating applied by means of arc wire spraying, plasma spraying or flame spraying.
  • typical bearing metal alloys come into question, including in particular bronze, brass, an aluminum bronze or an aluminum-bismuth alloy.
  • the thermally sprayed crankshaft bearing is formed from a plurality of thermally sprayed layers.
  • Different bearing metal alloys are used.
  • the last or uppermost sprayed layer may consist of an aluminum-bismuth alloy, while the underlying, previously sprayed layer is formed of a bearing alloy such as bronze or brass.
  • crankshaft, connecting rod and piston pin components of the lightweight UHC lightweight construction crank mechanism can be produced by hot forming in the temperature range 850 to 1250 ° C under air.
  • Hot working may generally take place in air in the range of 800 to 1250 ° C, since the reduced tendency to scale due to the Al and Si content of the UHC steel, no special inert gas atmosphere is required.
  • the temperature range of 920 to 1250 ° C is preferred: The Mn content increases the ductility, thereby eliminating the embrittling effect of the Si and thus counteract the cracking on the surface during hot working.
  • tempering at room temperature is possible after hot forming.
  • the lightweight crankshaft engine manufacturing method of the present invention as described above comprises the steps of hot working UHC light steel starting materials in a temperature range of 850 to 1250 ° C under air around the crankshaft, connecting rod and piston pin to manufacture. Then at least the large connecting rod eye is provided with one or more storage layers: This is done by thermal spray coating. Parallel to this, the piston pin is coated.
  • crankshaft is placed in the large connecting rod eye of the connecting rod and the piston pin in the small connecting rod eye. Thanks to the coatings, despite the material-selection-based reduction of the moving masses achieved, an improved frictional behavior and thereby also an increased agility of the engine is achieved.
  • the thermal spray coating by means of arc wire spraying, plasma spraying or flame spraying, wherein at least one bearing metal alloy, in particular a Bronze, brass, an aluminum bronze or an aluminum-bismuth alloy is applied.
  • the bearing metal alloy in particular the bronze or brass is applied, and then the surface of the large connecting rod forming sprayed layer of an aluminum-bismuth alloy.

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  • Engineering & Computer Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Mechanical Engineering (AREA)
  • General Engineering & Computer Science (AREA)
  • Materials Engineering (AREA)
  • Metallurgy (AREA)
  • Organic Chemistry (AREA)
  • Physics & Mathematics (AREA)
  • Plasma & Fusion (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Crystallography & Structural Chemistry (AREA)
  • Thermal Sciences (AREA)
  • Ocean & Marine Engineering (AREA)
  • Ceramic Engineering (AREA)
  • Combustion & Propulsion (AREA)
  • Shafts, Cranks, Connecting Bars, And Related Bearings (AREA)

Abstract

The present invention makes available a lightweight crank drive having components made of a lightweight steel which has a reduced density and has an ultra-high carbon content, and the method for manufacturing same. The lightweight crank drive comprises a crankshaft, a connecting rod with a large connecting eyelet and a small connecting eyelet, and a piston pin, wherein the crankshaft is mounted in the large connecting eyelet, and the piston pin is mounted in the small connecting eyelet. All the components, the crankshaft, connecting rod and pin bolt, here are composed of the UHC lightweight steel. In addition, the crankshaft bearing in the large connecting eyelet is made available by at least one thermal spray layer, and the piston pin has a urea coating.

Description

Leichtbau-Kurbeltrieb und Herstellungsverfahren desselben  Lightweight crankshaft and manufacturing process thereof
Die Erfindung betrifft einen Leichtbau-Kurbeltrieb mit Komponenten aus ultrahochkohlen- stoffhaltigem Leichtbaustahl für einen Verbrennungsmotor, sowie ein Verfahren zu dessen Herstellung. The invention relates to a lightweight crank mechanism with components made of ultra high carbon lightweight steel for an internal combustion engine, and a method for its production.
Das Gewicht von Verbrennungsmotoren hängt generell auch vom Hubvolumen ab. Abhängig von Motorkonzept und Zylinderanordnung besteht bei gleichem Hubraum allerdings eine große Streubreite des Motorgewichts, abhängig von der konstruktiven und materiellen Beschaffenheit der Komponenten. Herkömmlicherweise werden zur Fertigung der Kurbeltriebkomponenten Kurbelwelle, Pleuel und Kolbenbolzen etwa klassische Stahlwerkstoffe verwendet, beispielsweise der Stahl C70 für die Kurbelwelle, und damit schwere Werkstoffe. Der Einsatz eines ultrahochkohlenstoffhaltigen (Ultra High Carbon) Leichtbaustahls, kurz UHC-Leichtbaustahls, ist für die Herstellung von Bauteilen allgemein für Verbrennungsmotoren und Getriebekomponenten von Kraftfahrzeugen bekannt. The weight of combustion engines generally also depends on the stroke volume. Depending on the engine concept and cylinder arrangement, however, there is a large spread of engine weight for the same displacement, depending on the structural and material characteristics of the components. Conventionally, for the production of the crankshaft drive components crankshaft, connecting rod and piston pin about classic steel materials used, for example, the steel C70 for the crankshaft, and thus heavy materials. The use of ultra high carbon (UHC) lightweight structural steel is known for the manufacture of components generally for internal combustion engines and transmission components of automobiles.
So beschreibt DE 10 2006 041 902 A1 einen UHC-Leichtbaustahl mit verbesserter Zunderbeständigkeit, dessen Zusammensetzung durch 1 bis 1 ,6 Gew.-% C, 5 bis 10 Gew.-% AI, 0,5 bis 3 Gew.-% Cr und 0,1 bis 2,8 Gew.-% Si sowie dem Rest Eisen und üblichen stahlbegleitenden Verunreinigungen gekennzeichnet ist. Die dort offenbarte Stahlzusammensetzung bezieht sich nicht auf spezielle Bauteile. For example, DE 10 2006 041 902 A1 describes a UHC lightweight structural steel with improved scale resistance, the composition of which comprises from 1 to 1, 6% by weight C, 5 to 10% by weight Al, 0.5 to 3% by weight Cr and 0.1 to 2.8 wt .-% Si and the remainder iron and common steel-accompanying impurities is characterized. The steel composition disclosed therein does not refer to specific components.
Auch in DE 10 2008 032 024 A1 ist ein dichtereduzierter UHC-Leichtbaustahl offenbart, dessen Zusammensetzung 0,7 bis 1 ,6 Gew.-% C, 5 bis 12 Gew.-% AI, 0 bis 0,4 Gew.-% Cr und 0,01 bis 2,8 Gew.-% Si sowie stabilisierende Legierungselemente unterhalb 1 Gew.-% und dem Rest Eisen und übliche stahlbegleitende Verunreinigungen aufweist. Dort wird aus Gewichtsersparnisgründen vorgeschlagen, Fahrwerksbauteile, Getriebeteile, Zahnräder oder Motorkomponenten für Kraftfahrzeuge aus UHC-Leichtbaustahl zu fertigen. Aus dem genannten Stand der Technik ist bekannt, dass UHC-Stähle aufgrund ihres relativ hohen Kohlenstoffgehalts nach geeigneter thermischer und mechanischer Vorbehandlung superplastische Eigenschaften aufweisen können. Bei einer Umformung in dem superplastischen Bereich, der bei etwa 600 °C beginnt und gerade unterhalb der A^Tempe- ratur des perlitischen Eutektikums, also bei 723 °C (bei unlegiertem Stahl) endet, können Dehnwerte von einigen 100 bis 1000 % in Bezug auf Dehnwerte nicht superplastischer Materialien erreicht werden. Werden dabei jedoch die optimale Temperatur und/oder Umformgeschwindigkeit überschritten, so findet eine Zerstörung des Gefüges statt, es kann zu Verzunderungen und unerwünschter Graphitbildung kommen. DE 10 2008 032 024 A1 also discloses a density-reduced UHC lightweight structural steel whose composition contains 0.7 to 1, 6% by weight C, 5 to 12% by weight Al, 0 to 0.4% by weight Cr and 0.01 to 2.8 wt .-% Si and stabilizing alloying elements below 1 wt .-% and the balance iron and common steel-accompanying impurities. There is proposed for weight saving reasons to manufacture suspension components, gear parts, gears or engine components for motor vehicles made of UHC lightweight steel. From the cited prior art it is known that UHC steels can have superplastic properties due to their relatively high carbon content after suitable thermal and mechanical pretreatment. In the case of forming in the superplastic region, which begins at about 600 ° C. and ends just below the temperature of the pearlitic eutectic, that is to say at 723 ° C. (for unalloyed steel), expansion values of a few 100 to 1000% can be obtained on elongation values of non-superplastic materials can be achieved. If, however, the optimum temperature and / or forming speed are exceeded, destruction of the microstructure takes place, resulting in scaling and undesired formation of graphite.
Ausgehend von diesem Stand der Technik ergibt sich die Aufgabe, einen Leichtbau-Kurbeltrieb zu schaffen, der durch Reduktion der bewegten Massen ein verbessertes Reibverhalten und dadurch auch eine gesteigerte Agilität des Motors bereitstellt. Starting from this prior art, the object is to provide a lightweight crank mechanism, which provides by reducing the moving masses an improved friction behavior and thereby also increased agility of the engine.
Diese Aufgabe wird durch einen Leichtbau-Kurbeltrieb mit den Merkmalen des Anspruchs 1 gelöst. This object is achieved by a lightweight crank mechanism with the features of claim 1.
Entsprechend ergibt sich die Aufgabe der Schaffung eines geeigneten Fertigungsverfahrens für einen derartigen Leichtbau-Kurbeltrieb. Accordingly, the task of creating a suitable manufacturing process for such a lightweight crank mechanism results.
Das Verfahren mit den Merkmalen des Anspruchs 8 löst diese Aufgabe. The method with the features of claim 8 solves this problem.
Weiterbildungen der Vorrichtung und des Verfahrens sind in den entsprechenden Unteransprüchen ausgeführt. Further developments of the device and the method are carried out in the corresponding subclaims.
Die Komponenten des erfindungsgemäßen Leichtbau-Kurbeltriebs sind aus dichtereduziertem ultrahochkohlenstoffhaltigen Leichtbaustahl beschaffen, was vorteilhaft zur Reduzierung des Gewichtes des Kurbeltriebes ist. Der Leichtbau-Kurbeltrieb besteht aus Kurbelwelle, Pleuel mit großem und kleinem Pleuelauge und Kolbenbolzen, wobei die Kurbelwelle in dem großen Pleuelauge und der Kolbenbolzen in dem kleinen Pleuelauge gelagert ist. Zudem wird das Kurbelwellenlager im großen Pleuelauge durch eine oder mehrere thermische Spritzschichten gebildet, so dass der Verzicht auf eine Lagerschale zusätzlich zur Gewichtsersparnis beiträgt. The components of the lightweight crank mechanism according to the invention are obtained from density-reduced ultra-high carbon-containing lightweight steel, which is advantageous for reducing the weight of the crank mechanism. The lightweight crank mechanism consists of crankshaft, connecting rod with large and small connecting rod and piston pin, the crankshaft is mounted in the large connecting rod and the piston pin in the small connecting rod. In addition, the crankshaft bearing is formed in the large connecting rod by one or more thermal spray coatings, so that the waiver of a bearing shell also contributes to weight savings.
Ferner ist der Kolbenbolzen des erfindungsgemäßen Leichtbau-Kurbeltriebs mit einer Hartstoff-Beschichtung ausgestattet, so dass auch im kleinen Pleuelauge gewichtsmindernd auf eine Lagerschale verzichtet werden kann. Das Gewicht des Kurbeltriebs kann dadurch bei einem V6-Ottomotor um ca. 11 % verringert werden, so dass an diesem Motortyp beispielsweise bis zu 3,8 kg eingespart werden können. Neben Kraftstoff-Verbrauchsvorteilen führt die Reduktion der bewegten Massen des Kurbeltriebs zu weniger Reibung, was sich in einer Steigerung der Agilität des Motors bemerkbar macht. Furthermore, the piston pin of the lightweight crank mechanism according to the invention is equipped with a hard coating, so that even in the small connecting rod eye weight-reducing can be dispensed with a bearing shell. The weight of the crank drive can be reduced by about 11% in a V6 gasoline engine, so that can be saved on this type of engine, for example, up to 3.8 kg. In addition to fuel consumption advantages, the reduction of the moving masses of the crank mechanism leads to less friction, which manifests itself in an increase in the agility of the engine.
Eine geeignete Zusammensetzung eines dichtereduzierten UHC-Leichtbaustahls, aus dem die Kurbeltriebkomponenten Kurbelwelle, Pleuel und Kolbenbolzen erfindungsgemäß bestehen, umfasst von 0,7 bis 2,0 Gew.-% C; 5,0 bis 12,0 Gew.-% AI; 0,01 bis 2,8 Gew.- % Si; 0 bis 2,0 Gew.-% Cr; 1 ,0 bis 5,0 Gew.-% Mn sowie Fe bis zum Ausgleich der 100 Gew.-%. Ferner können stahltypische Verunreinigungsspuren enthalten sein. A suitable composition of a reduced-density UHC lightweight steel, from which the crankshaft components, crankshaft, connecting rod and piston pin according to the invention consist, comprises from 0.7 to 2.0 wt .-% C; 5.0 to 12.0% by weight of Al; 0.01 to 2.8% by weight of Si; 0 to 2.0 wt% Cr; 1, 0 to 5.0 wt .-% Mn and Fe to compensate for the 100 wt .-%. Furthermore, steel-typical contamination traces may be included.
Der hohe Anteil an Aluminium (AI) trägt zur Dichtereduktion bei, so dass der erfindungsgemäße Leichtbaustahl vorteilhaft gerade zur Herstellung von Leichtbaukomponenten im Kraftfahrzeugbau eingesetzt werden kann. Durch den hohen AI-Anteil werden die Ai-Um- wandlungstemperatur und damit die maximale superplastische Verarbeitungstemperatur erhöht. Dies wird durch eine geringe Erhöhung des Silizium (Si-) -Anteils noch verstärkt, wobei Silizium zusätzlich zur Dichteverringerung beiträgt, hier jedoch die Verschlechterung der mechanischen Eigenschaften durch Zulegieren von Si berücksichtigt werden muss. So kann über die zulegierten Si- und AI-Anteile eine optimale Ai-Umformtempe- ratur, die hohe Umformgeschwindigkeiten ohne Änderungen bzw. Schädigungen des Ge- füges erlaubt, eingestellt werden. Ferner wird durch den hohen AI-Anteil die Zunderbildung bei den erhöhten Temperaturen der Warmumformung verringert, was auch durch den Si-Anteil unterstützt wird. The high proportion of aluminum (AI) contributes to the reduction in density, so that the lightweight structural steel according to the invention can be advantageously used just for the production of lightweight components in the automotive industry. The high Al content increases the Ai transformation temperature and thus the maximum superplastic processing temperature. This is further enhanced by a small increase in the silicon (Si) content, with silicon additionally contributing to the reduction in density, but here the deterioration of the mechanical properties must be taken into account by alloying Si. Thus, via the alloyed Si and AI components, an optimum Ai transformation temperature, which allows high deformation rates without changes or damage to the structure, can be set. Furthermore, due to the high proportion of Al, the formation of scale at the elevated temperatures of the hot working is reduced, which is also supported by the Si content.
Durch das Zulegieren von Mn von bis zu 5 Gew.-% wird die Sprödigkeit des dichtereduzierten UHC-Leichtbaustahls mit dem hohen AI-Anteil von bis zu 10 Gew.-% verringert beziehungsweise seine Duktilität erhöht, so dass während eines Warmumformens wie Schmieden oder Walzen kaum Oberflächenrisse entstehen und ein so hergestellter Stahlrohling bei Raumtemperatur zur Behebung von entstandenen Verzügen gerichtet werden kann. Diese dichtereduzierte UHC-Leichtbaustahl-Zusammensetzung weist ein stabiles superplastisches Gefüge auf, mit hinsichtlich der Duktilität für eine gute Warmund Kaltumformbarkeit verbesserten mechanischen Eigenschaften, und weist dabei nur einen geringen oder gar keinen Anteil an teuren Legierungselementen wie Ni, Mo, V und/oder Sn auf. Auch der geringe Anteil an Cr - unter Umständen kann auf Chrom auch verzichtet werden - wirkt sich Kosten verringernd aus. Der erhöhte Mangan (Mn)-Anteil verhindert die bzw. wirkt der durch Zulegieren von Si normalerweise bedingte Verschlechterung der mechanischen Eigenschaften bei Raumtemperatur entgegen, die sich in einer stark versprödenden Wirkung zeigen. Der Mangan-Anteil trägt ferner dazu bei, die unerwünschte Graphitbildung zu hemmen, die aufgrund des hohen Anteils an AI und Si begünstigt ist. Zum Zweck der Unterdrückung der Graphitbildung kann das Zulegieren eines auf die Anteile an AI, Si und Mn abgestimmten Cr-Anteils sinnvoll sein. By alloying Mn of up to 5% by weight, the brittleness of the reduced density UHC lightweight steel with the high Al content of up to 10% by weight is reduced or its ductility increased, so that during hot forming such as forging or rolling hardly any surface cracks occur and a steel blank made in this way can be directed at room temperature to remedy any distortions. This density-reduced UHC lightweight structural composition has a stable superplastic texture, with mechanical properties improved in ductility for good hot and cold workability, with little or no contribution to expensive alloying elements such as Ni, Mo, V and / or Sn on. Even the low proportion of Cr - under certain circumstances can be dispensed with chrome - has a cost-reducing effect. The increased manganese (Mn) content prevents the deterioration of the mechanical properties at room temperature, which is normally caused by the addition of Si, and which has a strongly embrittling effect. The manganese content also helps to inhibit unwanted graphitization, which is favored due to the high content of Al and Si. For the purpose of suppressing the formation of graphite, it may be useful to alloy in a proportion of Cr coordinated to the proportions of Al, Si and Mn.
Der Gefügezustand eines UHC-Stahls nach seiner metallurgischen Herstellung ermöglicht in der Regel keine hohe Umformgeschwindigkeit bei der Warmumformung. Dazu ist ein Gefüge mit superplastischen Eigenschaften erforderlich. Superplastische Umformungen sind im Vergleich mit Warmumformungsprozessen jedoch weniger wirtschaftlich, eine Abweichung von dem optimalen superplastischen Gefüge ist akzeptabel, wenn eine homogene, feinkörnige, sphäroide Karbidverteilung in einer ebenfalls feinkörnigen Ferritmatrix vorliegt, wobei sowohl Karbid- als auch Ferritphasen gegenüber Kornwachstum und Graphitbildung stabil sind. Beispielhafte Korngrößen der Gefüge liegen unter 10 μιη, etwa mit einer mittleren Korngröße von weniger als 1 ,5 μιη. Ein überwiegender Kornanteil ist sphäroid, ein geringer lamellarer Karbid-Anteil wirkt sich nicht nachteilig auf die Eigenschaften des UHC-Stahls aus. The structural state of a UHC steel after its metallurgical production usually does not allow a high forming rate during hot forming. This requires a structure with superplastic properties. However, superplastic forming operations are less economical compared to hot forming processes, and deviation from the optimal superplastic structure is acceptable when a homogeneous, fine grained, spheroidal carbide distribution is present in a fine-grained ferrite matrix as well, with both carbide and ferrite phases being stable to grain growth and graphitization. Exemplary particle sizes of the microstructure are below 10 μm, for example with an average particle size of less than 1.5 μm. A predominant grain content is spheroidal, a low lamellar carbide content does not adversely affect the properties of the UHC steel.
AI und Si stabilisieren die gebildeten, gleichmäßig verteilten Phasen, die Hauptphase a- Ferrit und Nebenphasen aus -Carbiden, und verhindern Kornwachstum während des Warmumformens. Die gewünschte Phasenbildung des Gefüges mit feinen Kristalliten, bzw. Körnern kann mittels einer geeigneten thermo-mechanischen Behandlung erreicht werden. Der UHC-Leichtbaustahl weist auch bei Raumtemperatur gute Bruchdehnungsund Festigkeitswerte auf, das Gefüge mit den überwiegend sphäroiden Phasen zeigt bei Kaltumformung kaum oder keine Rissbildung. Al and Si stabilize the formed, uniformly distributed phases, the main phase a-ferrite and minor phases of carbides, and prevent grain growth during hot working. The desired phase formation of the microstructure with fine crystallites or grains can be achieved by means of a suitable thermo-mechanical treatment. The UHC lightweight steel has good elongation at break and strength values even at room temperature, the structure with the predominantly spheroidal phases shows little or no crack formation during cold forming.
Zur Herstellung eines superplastischen Gefüges kann nach einer Austenitisierung bei einer Temperatur oberhalb der Austenitisierungstemperatur, die je nach C-, Si-, AI- und Cr- Anteil variiert und bei der eine homogene Verteilung des Kohlenstoffs und der Begleitelemente in der groben γ-Phase stattfindet, die Abkühlung während einer Heißumformung bis unter die Ai-Temperatur durchgeführt werden, an die sich ein Warmumformen oberhalb A^Temperatur mit nachfolgendem Abkühlen anschließt. Dadurch werden die sphäroiden κ-Karbide erzeugt. In einer weiteren Ausführungsform des erfindungsgemäßen Kurbeltriebs aus UHC-Stahl- komponenten besteht eine weitere geeignete Zusammensetzung des UHC-Leichtbau- stahls aus 1 ,0 bis 1 ,6 Gew.-% C; 7,0 bis 10,0 Gew.-% AI; 0,01 bis 0,6 Gew.-% Si; 0 bis 1 ,5 Gew.-% Cr; 2,0 bis 3,0 Gew.-% Mn und dem zu 100 Gew.-% ausgleichenden Anteil Fe sowie gegebenenfalls mit den stahltypischen Verunreinigungsspuren. To produce a superplastic structure, after austenitizing at a temperature above the austenitizing temperature, which varies depending on the C, Si, Al and Cr contents and in which a homogeneous distribution of the carbon and the accompanying elements takes place in the coarse γ phase , the cooling is carried out during a hot forming to below the Ai temperature, followed by a hot forming above A ^ temperature followed by cooling. As a result, the spheroid κ-carbides are produced. In a further embodiment of the crank drive according to the invention made of UHC steel components, a further suitable composition of the UHC lightweight steel consists of 1, 0 to 1, 6 wt .-% C; 7.0 to 10.0% by weight of Al; 0.01 to 0.6% by weight of Si; 0 to 1, 5 wt .-% Cr; From 2.0 to 3.0% by weight of Mn and to the proportion of Fe equal to 100% by weight and, if appropriate, with the steel-typical traces of contamination.
Bei diesen Verunreinigungsspuren kann es sich beispielsweise um Ni, Mo, Nb, V und/ oder Cu handeln. In der Regel liegen deren Anteile unter 1 Gew.-%. These traces of contamination may be, for example, Ni, Mo, Nb, V and / or Cu. As a rule, their proportions are less than 1 wt .-%.
Der Kurbeltrieb mit den aus UHC-Stahl gefertigten Komponenten Kurbelwelle, Pleuel und Kolbenbolzen genügt hohen thermischen und mechanischen Ansprüchen und trägt zur Leichtbauweise zur Verringerung des Kraftstoffverbrauchs bei. The crank mechanism with the components made of UHC steel crankshaft, connecting rod and piston pin meets high thermal and mechanical demands and contributes to the lightweight construction to reduce fuel consumption.
Generell können zur Bildung des erfindungsgemäßen Kurbeltriebs mit thermisch gespritztem Kurbelwellenlager und Hartstoff beschichtetem Kolbenbolzen auch UHC-Leichtbau- stähle als Werkstoff für die Komponenten verwendet werden, wie sie im Stand der Technik beschrieben sind. In general, UHC lightweight steels can also be used as the material for the components, as described in the prior art, to form the crank drive according to the invention with a thermally sprayed crankshaft bearing and a hard-coated piston pin.
Eine weitere Ausführungsform des erfindungsgemäßen Leichtbau-Kurbeltriebs bezieht sich auf die Hartstoff-Beschichtung des Kolbenbolzens. Der Kolbenbolzen, der den Kolben mit dem Pleuel verbindet, kann mit sehr geringem Spiel schwimmend im kleinen Pleuelauge gelagert sein. Um dort auf eine Lagerschale verzichten zu können, ist der Kolbenbolzen von der Hartstoff-Beschichtung umgeben. Bei der Hartstoff-Beschichtung kann es sich um gängige Hartschicht-Materialien wie Hartmetall, Metallcarbid, Keramik oder insbesondere amorphen, diamantähnlichen Kohlenstoff (Diamond Like Carbon, DLC) handeln. Another embodiment of the lightweight crank mechanism according to the invention relates to the hard material coating of the piston pin. The piston pin, which connects the piston to the connecting rod, can be mounted floating in the small connecting rod eye with very little play. To be able to do without a bearing shell, the piston pin is surrounded by the hard material coating. The hard-material coating can be conventional hard-layer materials such as hard metal, metal carbide, ceramic or in particular amorphous, diamond-like carbon (DLC).
Die als Ersatz für eine Lagerschale im großen Pleuelauge eingesetzte thermische Spritzschicht, die das Kurbelwellenlager bildet, kann eine mittels Lichtbogendrahtspritzen, Plasmaspritzen oder Flammspritzen aufgebrachte Spritzschicht sein. The thermal spray coating used as a replacement for a bearing shell in the large connecting rod eye, which forms the crankshaft bearing, may be a sprayed coating applied by means of arc wire spraying, plasma spraying or flame spraying.
Als Werkstoff zur Bildung der thermischen Spritzschicht kommen typische Lager-Metalllegierungen in Frage, darunter insbesondere Bronze, Messing, eine Aluminiumbronze oder eine Aluminium-Wismut-Legierung. As a material for forming the thermal spray layer typical bearing metal alloys come into question, including in particular bronze, brass, an aluminum bronze or an aluminum-bismuth alloy.
In einer Variante kann vorgesehen sein, dass das thermisch gespritzte Kurbelwellenlager aus mehreren thermisch gespritzten Schichten gebildet wird. Dabei können unterschiedli- che Lager-Metalllegierungen zum Einsatz kommen. So kann etwa die letzte oder auch oberste Spritzschicht aus einer Aluminium-Wismut-Legierung bestehen, während die darunter liegende, zuvor gespritzte Schicht aus einer Lagerlegierung wie Bronze oder Messing gebildet wird. In a variant, it can be provided that the thermally sprayed crankshaft bearing is formed from a plurality of thermally sprayed layers. Different bearing metal alloys are used. For example, the last or uppermost sprayed layer may consist of an aluminum-bismuth alloy, while the underlying, previously sprayed layer is formed of a bearing alloy such as bronze or brass.
Die Komponenten Kurbelwelle, Pleuel und Kolbenbolzen des Leichtbau-Kurbeltriebs aus dem UHC-Leichtbaustahl können durch eine Warmumformung im Temperaturbereich von 850 bis 1250 °C unter Luft hergestellt werden. The crankshaft, connecting rod and piston pin components of the lightweight UHC lightweight construction crank mechanism can be produced by hot forming in the temperature range 850 to 1250 ° C under air.
Die Warmumformung kann unter Luft generell im Bereich von 800 bis 1250 °C stattfinden, da durch die verringerte Verzunderungsneigung aufgrund des AI- und Si-Anteils des UHC-Stahls keine besondere Schutzgasatmosphäre erforderlich ist. Der Temperaturbereich von 920 bis 1250 °C ist allerdings bevorzugt: Der Mn-Anteil erhöht die Duktilität, hebt dadurch die versprödende Wirkung des Si auf und wirkt somit der Rissbildung an der Oberfläche während der Warmumformung entgegen. Zudem wird im Anschluss an die Warmumformung ein Richten bei Raumtemperatur ermöglicht. Hot working may generally take place in air in the range of 800 to 1250 ° C, since the reduced tendency to scale due to the Al and Si content of the UHC steel, no special inert gas atmosphere is required. However, the temperature range of 920 to 1250 ° C is preferred: The Mn content increases the ductility, thereby eliminating the embrittling effect of the Si and thus counteract the cracking on the surface during hot working. In addition, tempering at room temperature is possible after hot forming.
Mit dem UHC-Leichtbaustahl als Werkstoff zur Bildung der Kurbeltriebkomponenten lassen sich durch das superplastische Gefüge auch bei einer Warmumformung, die nicht unter superplastischen Bedingungen erfolgt, sehr hohe Umformgrade von 50 bis zu 300 % erreichen. With the UHC lightweight steel as a material for the formation of the crank drive components can be achieved by the superplastic structure even in a hot forming, which does not occur under superplastic conditions, very high degrees of deformation of 50 to 300%.
Kurz gefasst, umfasst das erfindungsgemäße Verfahren zur Herstellung eines Leichtbau- Kurbeltriebs wie er vorstehend beschrieben ist, die Schritte des Warmumformens von UHC-Leichtbaustahl-Ausgangsmaterialien in einem Temperaturbereich von 850 bis 1250 °C unter Luft, um die Kurbelwelle, den Pleuel und den Kolbenbolzen zu fertigen. Dann wird wenigstens das große Pleuelauge mit einer oder mehreren Lagerschichten versehen: Dies geschieht durch thermisches Spritzbeschichten. Parallel hierzu wird der Kolbenbolzen beschichtet. Briefly stated, the lightweight crankshaft engine manufacturing method of the present invention as described above comprises the steps of hot working UHC light steel starting materials in a temperature range of 850 to 1250 ° C under air around the crankshaft, connecting rod and piston pin to manufacture. Then at least the large connecting rod eye is provided with one or more storage layers: This is done by thermal spray coating. Parallel to this, the piston pin is coated.
Nun wird die Kurbelwelle in dem großen Pleuelauge des Pleuels und der Kolbenbolzen in dem kleinen Pleuelauge angeordnet. So wird dank der Beschichtungen trotz der erreichten materialwahlbasierten Reduktion der bewegten Massen ein verbessertes Reibverhalten und dadurch auch eine gesteigerte Agilität des Motors erreicht. Now, the crankshaft is placed in the large connecting rod eye of the connecting rod and the piston pin in the small connecting rod eye. Thanks to the coatings, despite the material-selection-based reduction of the moving masses achieved, an improved frictional behavior and thereby also an increased agility of the engine is achieved.
Das thermische Spritzbeschichten erfolgt mittels Lichtbogendrahtspritzen, Plasmaspritzen oder Flammspritzen, wobei zumindest eine Lager-Metalllegierung, insbesondere eine Bronze, Messing, eine Aluminiumbronze oder eine Aluminium-Wismut-Legierung aufgebracht wird. The thermal spray coating by means of arc wire spraying, plasma spraying or flame spraying, wherein at least one bearing metal alloy, in particular a Bronze, brass, an aluminum bronze or an aluminum-bismuth alloy is applied.
Es ist zu beachten, dass bei der Spritzschichtung des großen Pleuelauges mit mehr als zwei Schichten zunächst die Lager-Metalllegierung, insbesondere die Bronze oder das Messing aufgebracht wird, und dann die Oberfläche des großen Pleuelauges bildende Spritzschicht aus einer Aluminium-Wismut-Legierung. It should be noted that in the spray stratification of the large connecting rod with more than two layers first the bearing metal alloy, in particular the bronze or brass is applied, and then the surface of the large connecting rod forming sprayed layer of an aluminum-bismuth alloy.

Claims

Patentansprüche claims
1. Leichtbau-Kurbeltrieb mit Komponenten aus ultrahochkohlenstoffhaltigem 1. Lightweight crankshaft with components made from ultra high carbon
Leichtbaustahl (UHC-Leichtbaustahl),  Lightweight structural steel (UHC lightweight steel),
umfassend eine Kurbelwelle, ein Pleuel mit einem großen und einem kleinen Pleuelauge und einen Kolbenbolzen, wobei die Kurbelwelle in dem großen Pleuelauge und der Kolbenbolzen in dem kleinen Pleuelauge gelagert sind, dadurch gekennzeichnet, dass  comprising a crankshaft, a connecting rod with a large and a small connecting rod eye and a piston pin, wherein the crankshaft are mounted in the large connecting rod eye and the piston pin in the small connecting rod eye, characterized in that
- alle der Komponenten Kurbelwelle, Pleuel und Kolbenbolzen aus dem UHC- Leichtbaustahl bestehen und dass  - All of the components crankshaft, connecting rod and piston pin made of UHC lightweight steel and that
- der Kolbenbolzen eine Hartstoff-Beschichtung aufweist.  - The piston pin has a hard material coating.
2. Leichtbau-Kurbeltrieb nach Anspruch 1 , 2. lightweight crank mechanism according to claim 1,
dadurch gekennzeichnet, dass  characterized in that
das Kurbelwellenlager in dem großen Pleuelauge durch zumindest eine thermische Spritzschicht bereitgestellt ist.  the crankshaft bearing is provided in the large connecting rod eye by at least one thermal spray coating.
3. Leichtbau-Kurbeltrieb nach Anspruch 1 oder 2, 3. lightweight crank mechanism according to claim 1 or 2,
dadurch gekennzeichnet, dass  characterized in that
der UHC-Leichtbaustahl eine Zusammensetzung aufweist, die  the UHC lightweight steel has a composition which
- 0,7 bis 2,0 Gew.-% C,  From 0.7 to 2.0% by weight of C,
- 5,0 bis 12,0 Gew. -% AI,  From 5.0 to 12.0% by weight of Al,
- 0,01 bis 2,8 Gew.-% Si,  0.01 to 2.8% by weight of Si,
- 0 bis 2,0 Gew.-% Cr,  0 to 2.0% by weight Cr,
- 1 ,0 bis 5,0 Gew.-% Mn  - 1, 0 to 5.0 wt .-% Mn
- unvermeidliche Stahlbegleiter in Spuren und  - inevitable steel companions in traces and
einen die 100 Gew.-% ausgleichenden Restanteil an Fe enthält.  one containing the 100 wt .-% balancing residual content of Fe.
4. Leichtbau-Kurbeltrieb nach Anspruch 3, 4. lightweight crank mechanism according to claim 3,
dadurch gekennzeichnet, dass  characterized in that
die Zusammensetzung des UHC-Leichtbaustahls  the composition of the UHC lightweight steel
- 1 ,0 bis 1 ,6 Gew. -% C, - 7,0 bis 10,0 Gew.-% AI, - 1, 0 to 1, 6 wt. -% C, 7.0 to 10.0% by weight of Al,
- 0,01 bis 0,6 Gew.-% Si,  0.01 to 0.6% by weight of Si,
- 0 bis 1 ,5 Gew.-% Cr,  0 to 1.5 wt.% Cr,
- 2,0 bis 3,0 Gew.-% Mn  2.0 to 3.0% by weight of Mn
- unvermeidliche Stahlbegleiter in Spuren und  - inevitable steel companions in traces and
einen die 100 Gew.-% ausgleichenden Restanteil an Fe enthält.  one containing the 100 wt .-% balancing residual content of Fe.
5. Leichtbau-Kurbeltrieb nach zumindest einem der Ansprüche 1 bis 4, 5. lightweight crank mechanism according to at least one of claims 1 to 4,
dadurch gekennzeichnet, dass  characterized in that
die Hartstoff-Beschichtung des Kolbenbolzens aus Diamant, Hartmetall,  the hard material coating of the piston pin made of diamond, carbide,
Metallcarbid, Keramik, amorphem, diamantähnlichem Kohlenstoff oder einer Kombination der vorgenannten beschaffen ist.  Metal carbide, ceramic, amorphous, diamond-like carbon, or a combination of the foregoing.
6. Leichtbau-Kurbeltrieb nach zumindest einem der Ansprüche 2 bis 4, 6. lightweight crank mechanism according to at least one of claims 2 to 4,
dadurch gekennzeichnet, dass  characterized in that
die thermische Spritzschicht, die das Kurbelwellenlager bildet, eine mittels Lichtbogendrahtspritzen, Plasmaspritzen oder Flammspritzen aufgebrachte Spritzschicht ist.  the thermal spray coating forming the crankshaft bearing is a sprayed coating applied by means of electric arc wire spraying, plasma spraying or flame spraying.
7. Leichtbau-Kurbeltrieb nach zumindest einem der Ansprüche 2 bis 5, 7. Lightweight crank mechanism according to at least one of claims 2 to 5,
dadurch gekennzeichnet, dass  characterized in that
die thermische Spritzschicht durch eine Lager-Metalllegierung, insbesondere eine Bronze, Messing, eine Aluminiumbronze, eine Aluminium-Wismut-Legierung gebildet ist.  the thermal spray coating is formed by a bearing metal alloy, in particular a bronze, brass, an aluminum bronze, an aluminum-bismuth alloy.
8. Leichtbau-Kurbeltrieb nach zumindest einem der Ansprüche 2 bis 6, 8. lightweight crank mechanism according to at least one of claims 2 to 6,
dadurch gekennzeichnet, dass  characterized in that
das Kurbelwellenlager in dem großen Pleuelauge aus zumindest zwei thermischen Spritzschichten gebildet wird, die aus unterschiedlichen Lager-Metalllegierungen bestehen, und wobei insbesondere eine die Oberfläche des großen Pleuelauges bildende Spritzschicht durch eine Aluminium-Wismut-Legierung und die unter der Aluminium-Wismut-Legierungs-Spritzschicht liegende Schicht aus einer Lager- Metalllegierung, insbesondere aus einer Bronze oder aus Messing gebildet ist.  the crankshaft bearing in the large connecting rod eye is formed from at least two thermal spray coatings, which consist of different bearing metal alloys, and wherein in particular a spray layer forming the surface of the large connecting rod is formed by an aluminum-bismuth alloy and the aluminum-bismuth alloy Spray layer lying layer of a bearing metal alloy, in particular made of a bronze or brass is formed.
9. Verfahren zur Herstellung eines Leichtbau-Kurbeltriebs nach zumindest einem der Ansprüche 1 bis 8, 9. A method for producing a lightweight crank mechanism according to at least one of claims 1 to 8,
umfassend die Schritte - Warmumformen von UHC-Leichtbaustahl-Ausgangsmaterialien in einem Temperaturbereich von 850 bis 1250 °C unter Luft und Fertigen der Kurbelwelle, des Pleuels und des Kolbenbolzens, comprising the steps Hot forming of UHC light-weight steel starting materials in a temperature range of 850 to 1250 ° C in air and finishing the crankshaft, connecting rod and piston pin,
- thermisch Spritzbeschichten des großen Pleuelauges mit zumindest einer thermischen Spritzschicht und  - Thermal spray coating of the large connecting rod with at least one thermal spray layer and
- Beschichten des Kolbenbolzens mit der Hartstoff-Beschichtung,  Coating the piston pin with the hard material coating,
- dann Anordnen der Kurbelwelle in dem großen Pleuelauge des Pleuels und Anordnen des Kolbenbolzens in dem kleinen Pleuelauge.  - Then arranging the crankshaft in the large connecting rod eye of the connecting rod and arranging the piston pin in the small connecting rod eye.
10. Verfahren zur Herstellung eines Leichtbau-Kurbeltriebs nach Anspruch 9, 10. A method for producing a lightweight crank mechanism according to claim 9,
wobei das thermische Spritzbeschichten mittels Lichtbogendrahtspritzen, Plasmaspritzen oder Flammspritzen erfolgt, und wobei zumindest eine Lager-Metalllegierung, insbesondere eine Bronze, Messing, eine Aluminiumbronze oder eine Aluminium-Wismut-Legierung aufgebracht wird.  wherein the thermal spray coating by means of arc wire spraying, plasma spraying or flame spraying, and wherein at least one bearing metal alloy, in particular a bronze, brass, an aluminum bronze or an aluminum-bismuth alloy is applied.
11. Verfahren zur Herstellung eines Leichtbau-Kurbeltriebs nach zumindest einem der Ansprüche 9 oder 10, 11. A method for producing a lightweight crank mechanism according to at least one of claims 9 or 10,
wobei zwei oder mehr Spritzschichten thermisch auf das große Pleuelauge aufgebracht werden,  wherein two or more sprayed layers are applied thermally to the large connecting rod eye,
und wobei zuerst  and being first
die Lager-Metalllegierung, insbesondere die Bronze oder das Messing aufgebracht wird, und dann die Oberfläche des großen Pleuelauges bildende Spritzschicht aus einer Aluminium-Wismut-Legierung.  the bearing metal alloy, in particular the bronze or the brass is applied, and then the surface of the large connecting rod forming sprayed layer of an aluminum-bismuth alloy.
PCT/EP2011/005307 2010-11-17 2011-10-21 Lightweight crankdrive and method for manufacturing same WO2012065674A1 (en)

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