WO2013066924A1 - Coated piston and a method of making a coated piston - Google Patents

Coated piston and a method of making a coated piston Download PDF

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Publication number
WO2013066924A1
WO2013066924A1 PCT/US2012/062667 US2012062667W WO2013066924A1 WO 2013066924 A1 WO2013066924 A1 WO 2013066924A1 US 2012062667 W US2012062667 W US 2012062667W WO 2013066924 A1 WO2013066924 A1 WO 2013066924A1
Authority
WO
WIPO (PCT)
Prior art keywords
coating
piston
set forth
rim area
crown portion
Prior art date
Application number
PCT/US2012/062667
Other languages
English (en)
French (fr)
Inventor
Warran Boyd Lineton
Original Assignee
Federal-Mogul Corporation
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 Federal-Mogul Corporation filed Critical Federal-Mogul Corporation
Priority to BR112014010335A priority Critical patent/BR112014010335A2/pt
Priority to KR1020147014665A priority patent/KR101993684B1/ko
Priority to CN201280065072.3A priority patent/CN104024616A/zh
Priority to IN3942CHN2014 priority patent/IN2014CN03942A/en
Priority to JP2014539148A priority patent/JP6451318B2/ja
Priority to EP12791605.4A priority patent/EP2773860B8/en
Publication of WO2013066924A1 publication Critical patent/WO2013066924A1/en

Links

Classifications

    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F02—COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
    • F02F—CYLINDERS, PISTONS OR CASINGS, FOR COMBUSTION ENGINES; ARRANGEMENTS OF SEALINGS IN COMBUSTION ENGINES
    • F02F3/00—Pistons 
    • F02F3/10—Pistons  having surface coverings
    • F02F3/12—Pistons  having surface coverings on piston heads
    • F02F3/14—Pistons  having surface coverings on piston heads within combustion chambers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D5/00—Processes for applying liquids or other fluent materials to surfaces to obtain special surface effects, finishes or structures
    • C—CHEMISTRY; METALLURGY
    • C25—ELECTROLYTIC OR ELECTROPHORETIC PROCESSES; APPARATUS THEREFOR
    • C25D—PROCESSES FOR THE ELECTROLYTIC OR ELECTROPHORETIC PRODUCTION OF COATINGS; ELECTROFORMING; APPARATUS THEREFOR
    • C25D7/00—Electroplating characterised by the article coated
    • 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
    • F02B23/00—Other engines characterised by special shape or construction of combustion chambers to improve operation
    • F02B23/02—Other engines characterised by special shape or construction of combustion chambers to improve operation with compression ignition
    • F02B23/06—Other engines characterised by special shape or construction of combustion chambers to improve operation with compression ignition the combustion space being arranged in working piston
    • F02B23/0603—Other engines characterised by special shape or construction of combustion chambers to improve operation with compression ignition the combustion space being arranged in working piston at least part of the interior volume or the wall of the combustion space being made of material different from the surrounding piston part, e.g. combustion space formed within a ceramic part fixed to a metal piston head
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F02—COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
    • F02F—CYLINDERS, PISTONS OR CASINGS, FOR COMBUSTION ENGINES; ARRANGEMENTS OF SEALINGS IN COMBUSTION ENGINES
    • F02F3/00—Pistons 
    • F02F3/10—Pistons  having surface coverings
    • F02F3/12—Pistons  having surface coverings on piston heads
    • 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
    • F02B23/00—Other engines characterised by special shape or construction of combustion chambers to improve operation
    • F02B23/02—Other engines characterised by special shape or construction of combustion chambers to improve operation with compression ignition
    • F02B23/06—Other engines characterised by special shape or construction of combustion chambers to improve operation with compression ignition the combustion space being arranged in working piston
    • F02B23/0603—Other engines characterised by special shape or construction of combustion chambers to improve operation with compression ignition the combustion space being arranged in working piston at least part of the interior volume or the wall of the combustion space being made of material different from the surrounding piston part, e.g. combustion space formed within a ceramic part fixed to a metal piston head
    • F02B2023/0612—Other engines characterised by special shape or construction of combustion chambers to improve operation with compression ignition the combustion space being arranged in working piston at least part of the interior volume or the wall of the combustion space being made of material different from the surrounding piston part, e.g. combustion space formed within a ceramic part fixed to a metal piston head the material having a high temperature and pressure resistance, e.g. ceramic
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
    • F05C—INDEXING SCHEME RELATING TO MATERIALS, MATERIAL PROPERTIES OR MATERIAL CHARACTERISTICS FOR MACHINES, ENGINES OR PUMPS OTHER THAN NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES
    • F05C2201/00—Metals
    • F05C2201/04—Heavy metals
    • F05C2201/0403—Refractory metals, e.g. V, W
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
    • F05C—INDEXING SCHEME RELATING TO MATERIALS, MATERIAL PROPERTIES OR MATERIAL CHARACTERISTICS FOR MACHINES, ENGINES OR PUMPS OTHER THAN NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES
    • F05C2201/00—Metals
    • F05C2201/04—Heavy metals
    • F05C2201/0418—Noble metals
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
    • F05C—INDEXING SCHEME RELATING TO MATERIALS, MATERIAL PROPERTIES OR MATERIAL CHARACTERISTICS FOR MACHINES, ENGINES OR PUMPS OTHER THAN NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES
    • F05C2201/00—Metals
    • F05C2201/04—Heavy metals
    • F05C2201/0418—Noble metals
    • F05C2201/0421—Silver
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
    • F05C—INDEXING SCHEME RELATING TO MATERIALS, MATERIAL PROPERTIES OR MATERIAL CHARACTERISTICS FOR MACHINES, ENGINES OR PUMPS OTHER THAN NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES
    • F05C2201/00—Metals
    • F05C2201/04—Heavy metals
    • F05C2201/0418—Noble metals
    • F05C2201/0424—Gold
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
    • F05C—INDEXING SCHEME RELATING TO MATERIALS, MATERIAL PROPERTIES OR MATERIAL CHARACTERISTICS FOR MACHINES, ENGINES OR PUMPS OTHER THAN NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES
    • F05C2201/00—Metals
    • F05C2201/04—Heavy metals
    • F05C2201/0418—Noble metals
    • F05C2201/0427—Platinum group, e.g. Pt, Ir
    • 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
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02T—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION
    • Y02T10/00—Road transport of goods or passengers
    • Y02T10/10—Internal combustion engine [ICE] based vehicles
    • Y02T10/12—Improving ICE efficiencies

Definitions

  • the subject invention is related to pistons, and more precisely, to steel pistons for diesel engines.
  • a piston for a diesel engine including a crown portion fabricated of steel and presenting a combustion surface having a combustion bowl with a bowl rim area.
  • a coating including at least one of a noble metal and a refractory metal is selectively applied to at least a portion of the bowl rim area and substantially only to those selective portions of the bowl rim area.
  • the oxidation resistant coating is advantageous because it protects the steel base metal of the piston from oxidation and also is able to resist the pressures and temperatures of combustion.
  • the coating is preferably applied only to the portions of the upper surface of the piston in line with the fuel injectors when the piston is in a top-dead-center position. Thus, the material cost for the increased oxidation protection is minimized without compromising the utility of the piston.
  • Another aspect of the present invention provides for a method of making a piston for diesel engines including the step of preparing a crown portion of steel and having a combustion surface with a combustion bowl and a bowl rim area. The method continues with the step of selectively applying a coating including at least one of a noble metal and a refractory metal to substantially only the bowl rim area of the crown portion.
  • Yet another aspect of the present invention is a method of making a piston for diesel engines and wherein the step of selectively applying the coating onto the bowl rim area is further defined as electrodepositing the coating onto the bowl rim area of the crown portion with a wand applicator.
  • the metal applied to the piston is rhenium, a refractory metal which has a high melting temperature (3186°C), is resistant to chemical attack and is neither overly ductile nor overly brittle.
  • Figure 1 is a perspective and fragmentary view of an exemplary piston and shown with circles indicating the areas coated with a noble metal;
  • Figure 2 is a top and elevation view of the exemplary piston and shown with circles indicating the areas to be coated with the noble metal;
  • Figure 3 is a schematic view of an exemplary applicator applying a coating to a piston
  • Figure 4 is a schematic view of the exemplary piston of Figure 1 disposed within a cylinder bore of an exemplary diesel engine
  • Figure 5 is a cross-sectional and enlarged view of the exemplary piston of Figure 4 and centered around an area coated with the metal and with the thickness of the coating being exaggerated.
  • an exemplary piston 20 for use in a diesel engine 22 and constructed according to one aspect of the present invention is generally shown in Figures 1 and 2 and is shown as installed in a diesel engine 22 in Figure 4.
  • the exemplary piston 20 is of a monobloc design, i.e. it includes a crown portion 24 and a skirt portion 25 which are integrally connected to one another to present a one-piece piston 20 body.
  • the crown portion 24 includes a top, or combustion, surface having a combustion bowl 26 with a "Mexican hat” design and a combustion bowl rim area 28.
  • the piston 20 could alternately be formed of two or more pieces articulatedly or non-articulatedly coupled to one another and could have a combustion bowl 26 with any desirable shape.
  • the term "combustion bowl rim area 28" is used hereinafter to describe the upper edge of the combustion bowl 26 and the areas of the crown portion 24 substantially adjacent the upper edge of the combustion bowl 26 both inside of the combustion bowl 26 and surrounding the combustion bowl 26.
  • the crown portion 24 of the piston 20 is formed primarily or entirely of steel, e.g. 4140H steel or microalloyed steel.
  • the crown and skirt portions 24, 25 of the piston 20 body are preferably shaped through a precision (or investment) casting process and subsequently machined to its final form.
  • these portions 24, 25 of the piston 20 may be formed and shaped through any suitable process including, for example, forging or machining from a billet.
  • the exemplary piston 20 also includes a plurality of ring grooves 30 for receiving piston rings 32 (shown in Figure 4), which seal the piston 20 to a cylinder bore of the diesel engine 22.
  • a coating 34 is applied to the combustion surface of the crown portion
  • the coating 34 is substantially entirely of one or more noble or refractory metals (such as rhenium, gold, platinum, iridium, palladium, osmium, silver, rhodium and ruthenium), thereby protecting the coated portions of the base steel material of the crown portion 24 from oxidation. Specifically, the coating 34 is substantially only applied to the combustion surface at the combustion bowl rim area 28.
  • the coated portions 34 of the combustion bowl rim area 28 are generally in line with a spray of diesel fuel from a fuel injector 40 when the piston 20 is at a top dead center position.
  • the coating 34 protects the portions of the piston 20 that would otherwise be the most susceptible to oxidation during operation of the engine. It should also be appreciated that the specific locations along the combustion bowl rim area 28 that are coated could depend upon the type of fuel injector 40 in the cylinder and its orientation relative to the piston 20 in the cylinder bore. Alternately, the coating 34 may be applied to the entire combustion bowl rim area 28 if desired.
  • the coating 34 most preferably includes rhenium (a refractory metal) for its high melting point temperature (approximately 3 1 86°C). This is advantageous because during operation of the diesel engine 22, the coating 34 is directly exposed to the temperatures of combustion. Additionally, rhenium is advantageous because it is resistant to chemical attack and is neither overly ductile nor overly brittle. However, it should be appreciated that the coating 34 may alternately include other noble and/or refractory metals. For example, it might be desirable to formulate the coating 34 of various combinations of rhenium, ruthenium, palladium, osmium, iridium, platinum, rhodium, gold, silver, cobalt and nickel.
  • Locating the coating 34 substantially only on the combustion bowl rim area 28 is advantageous because it provides the piston 20 with sufficient resistance to oxidation in a cost effective manner since the amount of the noble metal used is kept to a minimum. Additionally, the coating 34 is preferably between one and one hundred microns (1 - 100 ⁇ ) in thickness. As such, the material costs for the improved oxidation resistance are very small. It should be appreciated that the specific portions of the combustion bowl rim area 28 coated with the noble metal could vary based on, for example, the number of fuel injectors 40 per cylinder of the engine, the types of fuel injectors 40, the orientations of the fuel injectors 40 relative to the piston 20 and the geometry of the piston 20.
  • the remainder of the combustion surface of the piston 20 may be uncoated or may be coated with one or more materials that are less costly than the noble metal coating 34.
  • the crown portion 24 should be thoroughly cleaned and activated. This is performed preferably with a voltage of between ten and fifteen Volts (10- 15 V) and may include an acid activator and intermediate rinsing steps.
  • a bond layer 44 is applied to the piston 20 between the steel base material of the crown portion 24 and the coating 34.
  • the bond layer 44 is preferably of nickel and is approximately one to ten microns (1- 10 ⁇ ) in thickness.
  • the bond layer 44 may be applied through any suitable process. It should be appreciated that materials other than nickel could alternately be used for the bond layer 44 and that the bond layer 44 may have any desirable thickness.
  • a mask (not shown) may be applied to the areas of the combustion surface that are not to receive the coating 34.
  • the noble metal and/or refractory metal coating of the exemplary embodiment is applied to the bond layer through a selective electrochemical metalizing process with a wand, pen or stylus applicator 46.
  • the exemplary applicator 46 includes an anode portion 38 of graphite and attached to a handle 48.
  • the anode portion 38 of the applicator 46 is preferably shaped similarly to the combustion bowl rim area 28 to more easily apply the coating 34 onto the piston 20.
  • the tip of the anode portion 38 is covered with a fabric wrap 50, such as polyester, cotton or scotchbrite.
  • a pump 52 (such as a peristalitic pump 52) is in fluid communication with the applicator 46 for delivering a noble or refractory metal solution to the fabric wrap 50.
  • the tip of the applicator 46 could be periodically dipped into the noble or refractory metal solution.
  • Another aspect of the present invention is a method of making a piston
  • the method includes the steps of preparing a crown portion 24 of steel and having a combustion surface with a combustion bowl 26 and a combustion bowl rim area 28.
  • the method continues with the step of selectively applying a coating 34 including at least one of a noble metal and a refractory metal to substantially only the combustion bowl rim area 28 of the crown portion 24.
  • the application of the noble and/or refractory metal coating 34 may be through, for example, electrodepositing or a slurry paste which is dried then melted with a laser.
  • any desirable process may be employed to apply the noble and/or refractory metal coating 34 onto the combustion bowl rim area 28 of the crown portion 24.
  • the noble and/or refractory metal coating 34 may be substantially entirely of one or more of the elements rhenium, gold, platinum, iridium, palladium, osmium, silver, rhodium and ruthenium.
  • the noble and/or refractory metal coating 34 is preferably applied onto the crown portion 24 to a thickness of between one and one hundred microns (1 -100 ⁇ ).
  • the method may also include the step of applying a bond layer 44 including nickel to the bowl rim before the step of selectively applying the noble metal coating 34 to the bowl rim and then applying the noble and/or refractory metal coating 34 onto the bond layer 44.
  • Yet another aspect of the present invention is another method of making a piston 20 for diesel engines 22.
  • the method includes the step of preparing a crown portion 24 of steel and having a combustion surface with a combustion bowl 26 and a combustion bowl rim area 28.
  • the method continues with electrodepositing a coating 34 including a noble metal and/or a refractory metal, and preferably being substantially only of one or more noble metals or refractory metals, onto substantially only the combustion bowl rim area 28 of the crown portion 24 with a wand applicator 46.
  • the crown portion 24 may either be held stationary while the wand applicator 46 is moved relative to it or vice versa.
  • the metal coating 34 may be substantially of one or more of the elements rhenium, gold, platinum, iridium, palladium, osmium, silver, rhodium and ruthenium.

Landscapes

  • Engineering & Computer Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Combustion & Propulsion (AREA)
  • General Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Electrochemistry (AREA)
  • Organic Chemistry (AREA)
  • Metallurgy (AREA)
  • Materials Engineering (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Ceramic Engineering (AREA)
  • Pistons, Piston Rings, And Cylinders (AREA)
  • Other Surface Treatments For Metallic Materials (AREA)
  • Combustion Methods Of Internal-Combustion Engines (AREA)
PCT/US2012/062667 2011-10-31 2012-10-31 Coated piston and a method of making a coated piston WO2013066924A1 (en)

Priority Applications (6)

Application Number Priority Date Filing Date Title
BR112014010335A BR112014010335A2 (pt) 2011-10-31 2012-10-31 pistão revestido e método de fabricação de um pistão revestido
KR1020147014665A KR101993684B1 (ko) 2011-10-31 2012-10-31 코팅처리된 피스톤 및 코팅처리된 피스톤을 제조하는 방법
CN201280065072.3A CN104024616A (zh) 2011-10-31 2012-10-31 涂层活塞以及一种制造涂层活塞的方法
IN3942CHN2014 IN2014CN03942A (GUID-C5D7CC26-194C-43D0-91A1-9AE8C70A9BFF.html) 2011-10-31 2012-10-31
JP2014539148A JP6451318B2 (ja) 2011-10-31 2012-10-31 被覆されたピストンおよび被覆されたピストンを製造する方法
EP12791605.4A EP2773860B8 (en) 2011-10-31 2012-10-31 Coated piston and a method of making a coated piston

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US201161553529P 2011-10-31 2011-10-31
US61/553,529 2011-10-31

Publications (1)

Publication Number Publication Date
WO2013066924A1 true WO2013066924A1 (en) 2013-05-10

Family

ID=47228036

Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/US2012/062667 WO2013066924A1 (en) 2011-10-31 2012-10-31 Coated piston and a method of making a coated piston

Country Status (8)

Country Link
US (1) US8863720B2 (GUID-C5D7CC26-194C-43D0-91A1-9AE8C70A9BFF.html)
EP (1) EP2773860B8 (GUID-C5D7CC26-194C-43D0-91A1-9AE8C70A9BFF.html)
JP (1) JP6451318B2 (GUID-C5D7CC26-194C-43D0-91A1-9AE8C70A9BFF.html)
KR (1) KR101993684B1 (GUID-C5D7CC26-194C-43D0-91A1-9AE8C70A9BFF.html)
CN (2) CN109339970A (GUID-C5D7CC26-194C-43D0-91A1-9AE8C70A9BFF.html)
BR (1) BR112014010335A2 (GUID-C5D7CC26-194C-43D0-91A1-9AE8C70A9BFF.html)
IN (1) IN2014CN03942A (GUID-C5D7CC26-194C-43D0-91A1-9AE8C70A9BFF.html)
WO (1) WO2013066924A1 (GUID-C5D7CC26-194C-43D0-91A1-9AE8C70A9BFF.html)

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WO2017174143A1 (en) * 2016-04-08 2017-10-12 Volvo Truck Corporation A piston for a cylinder for an internal combustion engine

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USD713422S1 (en) * 2011-05-20 2014-09-16 Federal-Mogul Corporation Piston
USD704226S1 (en) * 2012-04-03 2014-05-06 Stealth Innovative Systems, Llc Piston for pneumatic automotive lifting device
EP2981379B1 (en) 2013-04-05 2019-05-15 Tenneco Inc. Method of making a piston body using additive manufacturing techniques
US10738731B2 (en) 2013-11-07 2020-08-11 Tenneco Inc. Monolithic, galleryless piston and method of construction thereof
CN105940213B (zh) 2013-11-07 2019-11-26 天纳克股份有限公司 整体式无通道活塞及其构造方法
USD768207S1 (en) 2014-07-16 2016-10-04 Federal-Mogul Corporation Piston
JP6446973B2 (ja) * 2014-10-07 2019-01-09 トヨタ自動車株式会社 内燃機関
US20170145951A1 (en) * 2015-11-19 2017-05-25 Caterpillar Inc. Textured Piston
US10578050B2 (en) 2015-11-20 2020-03-03 Tenneco Inc. Thermally insulated steel piston crown and method of making using a ceramic coating
US10519854B2 (en) 2015-11-20 2019-12-31 Tenneco Inc. Thermally insulated engine components and method of making using a ceramic coating
US10273902B2 (en) * 2016-02-22 2019-04-30 Tenneco Inc. Insulation layer on steel pistons without gallery
US10119493B2 (en) * 2016-02-29 2018-11-06 Achates Power, Inc. Multi-layered piston crown for opposed-piston engines
US10578049B2 (en) * 2017-04-28 2020-03-03 Mahle International Gmbh Thermal barrier coating for engine combustion component
US20190136792A1 (en) * 2017-11-09 2019-05-09 GM Global Technology Operations LLC Bimetallic piston heads including thermal insulation coatings
WO2023070077A1 (en) * 2021-10-22 2023-04-27 Tenneco Inc. Engine piston having crevice catalyst

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