WO2022199828A1 - Nickel aluminium alloy compositions - Google Patents
Nickel aluminium alloy compositions Download PDFInfo
- Publication number
- WO2022199828A1 WO2022199828A1 PCT/EP2021/057906 EP2021057906W WO2022199828A1 WO 2022199828 A1 WO2022199828 A1 WO 2022199828A1 EP 2021057906 W EP2021057906 W EP 2021057906W WO 2022199828 A1 WO2022199828 A1 WO 2022199828A1
- Authority
- WO
- WIPO (PCT)
- Prior art keywords
- composition
- valve seat
- hardener
- matrix material
- aluminium
- Prior art date
Links
- 239000000203 mixture Substances 0.000 title claims abstract description 71
- 229910000545 Nickel–aluminium alloy Inorganic materials 0.000 title description 3
- PXHVJJICTQNCMI-UHFFFAOYSA-N Nickel Chemical compound [Ni] PXHVJJICTQNCMI-UHFFFAOYSA-N 0.000 claims abstract description 36
- 239000011159 matrix material Substances 0.000 claims abstract description 36
- 239000004848 polyfunctional curative Substances 0.000 claims abstract description 30
- 239000004411 aluminium Substances 0.000 claims abstract description 22
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 claims abstract description 22
- 229910052782 aluminium Inorganic materials 0.000 claims abstract description 22
- 238000004372 laser cladding Methods 0.000 claims abstract description 20
- 229910052759 nickel Inorganic materials 0.000 claims abstract description 18
- UFGZSIPAQKLCGR-UHFFFAOYSA-N chromium carbide Chemical group [Cr]#C[Cr]C#[Cr] UFGZSIPAQKLCGR-UHFFFAOYSA-N 0.000 claims abstract description 11
- 229910003470 tongbaite Inorganic materials 0.000 claims abstract description 11
- AZDRQVAHHNSJOQ-UHFFFAOYSA-N alumane Chemical group [AlH3] AZDRQVAHHNSJOQ-UHFFFAOYSA-N 0.000 claims abstract description 7
- 238000000034 method Methods 0.000 claims description 28
- 238000005253 cladding Methods 0.000 claims description 25
- 239000002245 particle Substances 0.000 claims description 24
- 230000008569 process Effects 0.000 claims description 24
- 239000000758 substrate Substances 0.000 claims description 15
- 238000004519 manufacturing process Methods 0.000 claims description 10
- 239000011230 binding agent Substances 0.000 claims description 6
- 238000000151 deposition Methods 0.000 claims description 5
- 239000000463 material Substances 0.000 description 13
- 238000005266 casting Methods 0.000 description 9
- 229910052751 metal Inorganic materials 0.000 description 9
- 238000003754 machining Methods 0.000 description 7
- 239000002184 metal Substances 0.000 description 7
- 230000032798 delamination Effects 0.000 description 5
- 239000000843 powder Substances 0.000 description 5
- HBMJWWWQQXIZIP-UHFFFAOYSA-N silicon carbide Chemical compound [Si+]#[C-] HBMJWWWQQXIZIP-UHFFFAOYSA-N 0.000 description 5
- 229910010271 silicon carbide Inorganic materials 0.000 description 5
- NPXOKRUENSOPAO-UHFFFAOYSA-N Raney nickel Chemical compound [Al].[Ni] NPXOKRUENSOPAO-UHFFFAOYSA-N 0.000 description 4
- 229910045601 alloy Inorganic materials 0.000 description 4
- 239000000956 alloy Substances 0.000 description 4
- 238000002485 combustion reaction Methods 0.000 description 4
- 238000001816 cooling Methods 0.000 description 4
- 238000005520 cutting process Methods 0.000 description 4
- 238000011068 loading method Methods 0.000 description 4
- 238000001000 micrograph Methods 0.000 description 4
- UONOETXJSWQNOL-UHFFFAOYSA-N tungsten carbide Chemical compound [W+]#[C-] UONOETXJSWQNOL-UHFFFAOYSA-N 0.000 description 4
- 230000008021 deposition Effects 0.000 description 3
- 238000013461 design Methods 0.000 description 3
- 238000005299 abrasion Methods 0.000 description 2
- 238000005275 alloying Methods 0.000 description 2
- 230000008859 change Effects 0.000 description 2
- 239000002131 composite material Substances 0.000 description 2
- 239000012535 impurity Substances 0.000 description 2
- 238000012966 insertion method Methods 0.000 description 2
- 239000000155 melt Substances 0.000 description 2
- 238000012986 modification Methods 0.000 description 2
- 230000004048 modification Effects 0.000 description 2
- 229910000881 Cu alloy Inorganic materials 0.000 description 1
- 241001465754 Metazoa Species 0.000 description 1
- 238000007545 Vickers hardness test Methods 0.000 description 1
- 238000007792 addition Methods 0.000 description 1
- 230000004075 alteration Effects 0.000 description 1
- 230000005540 biological transmission Effects 0.000 description 1
- 239000011248 coating agent Substances 0.000 description 1
- 238000000576 coating method Methods 0.000 description 1
- 125000004122 cyclic group Chemical group 0.000 description 1
- 238000004512 die casting Methods 0.000 description 1
- 238000005553 drilling Methods 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 239000008187 granular material Substances 0.000 description 1
- 230000005484 gravity Effects 0.000 description 1
- 238000005552 hardfacing Methods 0.000 description 1
- 238000009413 insulation Methods 0.000 description 1
- 230000010354 integration Effects 0.000 description 1
- 230000003137 locomotive effect Effects 0.000 description 1
- 230000013011 mating Effects 0.000 description 1
- 238000002844 melting Methods 0.000 description 1
- 230000008018 melting Effects 0.000 description 1
- 239000007769 metal material Substances 0.000 description 1
- 150000002739 metals Chemical class 0.000 description 1
- 238000003801 milling Methods 0.000 description 1
- 230000003647 oxidation Effects 0.000 description 1
- 238000007254 oxidation reaction Methods 0.000 description 1
- 239000002994 raw material Substances 0.000 description 1
- 230000009467 reduction Effects 0.000 description 1
- 239000000126 substance Substances 0.000 description 1
- 238000006467 substitution reaction Methods 0.000 description 1
- 238000012360 testing method Methods 0.000 description 1
Classifications
-
- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C32/00—Non-ferrous alloys containing at least 5% by weight but less than 50% by weight of oxides, carbides, borides, nitrides, silicides or other metal compounds, e.g. oxynitrides, sulfides, whether added as such or formed in situ
- C22C32/0047—Non-ferrous alloys containing at least 5% by weight but less than 50% by weight of oxides, carbides, borides, nitrides, silicides or other metal compounds, e.g. oxynitrides, sulfides, whether added as such or formed in situ with carbides, nitrides, borides or silicides as the main non-metallic constituents
- C22C32/0052—Non-ferrous alloys containing at least 5% by weight but less than 50% by weight of oxides, carbides, borides, nitrides, silicides or other metal compounds, e.g. oxynitrides, sulfides, whether added as such or formed in situ with carbides, nitrides, borides or silicides as the main non-metallic constituents only carbides
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F1/00—Metallic powder; Treatment of metallic powder, e.g. to facilitate working or to improve properties
- B22F1/10—Metallic powder containing lubricating or binding agents; Metallic powder containing organic material
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F5/00—Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product
- B22F5/008—Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product of engine cylinder parts or of piston parts other than piston rings
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F7/00—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression
- B22F7/06—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression of composite workpieces or articles from parts, e.g. to form tipped tools
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F7/00—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression
- B22F7/06—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression of composite workpieces or articles from parts, e.g. to form tipped tools
- B22F7/08—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression of composite workpieces or articles from parts, e.g. to form tipped tools with one or more parts not made from powder
-
- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C19/00—Alloys based on nickel or cobalt
- C22C19/03—Alloys based on nickel or cobalt based on nickel
- C22C19/05—Alloys based on nickel or cobalt based on nickel with chromium
- C22C19/058—Alloys based on nickel or cobalt based on nickel with chromium without Mo and W
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
- F01L—CYCLICALLY OPERATING VALVES FOR MACHINES OR ENGINES
- F01L3/00—Lift-valve, i.e. cut-off apparatus with closure members having at least a component of their opening and closing motion perpendicular to the closing faces; Parts or accessories thereof
- F01L3/02—Selecting particular materials for valve-members or valve-seats; Valve-members or valve-seats composed of two or more materials
- F01L3/04—Coated valve members or valve-seats
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
- F01L—CYCLICALLY OPERATING VALVES FOR MACHINES OR ENGINES
- F01L2301/00—Using particular materials
Definitions
- the present disclosure relates to nickel aluminium alloy compositions. Aspects of the invention relate to nickel aluminium compositions for use in laser cladding and to processes for modifying a machined or cast aluminium part by laser cladding.
- valve seats upon which the valve poppet rests when the valve is closed during engine operation.
- the cylinder head is typically formed of aluminium as it is lightweight and durable that can be easily cast and machined. Nonetheless, the valve seat is typically exposed to high temperatures and friction due to cyclic impact loading with the poppet valve and sliding wear caused by the deflection of the poppet valve head under cylinder pressure during engine operation. Thus the valve seat is required to exhibit greater wear resistance than other portions of the cylinder head.
- the valve seat is provided with a cast valve seat insert to prevent excessive wear and breakage of the valve seat.
- valve seat to be driven into a pre-machined bore and held in place by means of a friction fit.
- valve seat inserts impose constraints on cylinder head design due to the space requirements to accommodate the inserts and the material required behind the valve seat to maintain the structural integrity of the cylinder head.
- Port geometry, intake and exhaust port opening geometry in addition to combustion chamber layout are such design elements that are constrained by the application of valve seats of an insert type.
- securing the valve seat by means of friction fit through an insertion method creates air gaps between the valve seat insert and the mating surface of the cylinder head. This can create an insulation layer that increases the temperature of the valve seat, reducing thermal transmission and increasing the temperature in the region surrounding the valve seat and the poppet valve.
- patent application US 4723518 A describes laying a copper alloy upon the valve seat surface using a laser cladding technique.
- the invention resides in a first aspect a composition for use in laser cladding a surface of a machined or cast aluminium part, the composition comprising a matrix material and a hardener, wherein the hardener is present in an amount of at least 1wt% and at most about 20wt% and the balance of the composition comprising the matrix material, wherein the matrix material comprises nickel and aluminium, and wherein the hardener is chromium carbide.
- composition further comprises and organic binder.
- composition in particulate form.
- particles typically have an average particle size in diameter of at least about 30 pm and at most about 150 pm.
- the composition is used in the manufacture of a valve seat surface within the cylinder head of an engine.
- the composition is applied to the surface of a valve seat, an intake port and/or an exhaust port via a laser cladding process.
- a further embodiment resides in a cylinder head for use in an engine comprising: an exhaust valve having a valve seat defining a surface thereon, wherein the valve seat surface is modified by the application the composition.
- a cylinder head for use in an engine comprising: an intake port defining a surface thereon, wherein the intake port surface is modified by the application the composition.
- the engine comprises an exhaust port defining a surface thereon, wherein the surface is modified by the application of the composition.
- the invention resides in a second aspect in a process for modifying a surface of a machined or cast aluminium part, the process comprising: providing a particulate composition that comprises a matrix material and a hardener, wherein the hardener is present in an amount of at least 1 wt% and at most about 20wt% and the balance of the composition comprising the matrix material, wherein the matrix material comprises nickel and aluminium, and wherein the hardener is chromium carbide; and depositing the composition on to the substrate via a laser cladding procedure in order to modify the surface of the part with a cladding layer.
- the particulate composition further comprises and an organic binder.
- the particles have an average particle size diameter of at least about 30 pm and at most about 150 pm.
- the depth of the cladding layer is at least about 1000 microns and at most about 2000 microns.
- composition is deposited upon the surface at a temperature of at least about 1200 °C and at most about 1500 °C.
- the surface is comprised within a valve seat, and/or the exhaust port, and/or the intake port.
- an engine comprises the cylinder head.
- a vehicle comprises the engine.
- Figure 1 shows a schematic representation of a (A) a cross section of a valve seat having a laser cladded surface and (B) cross section of a traditional cylinder valve seat; and Figure 2 shows electron microscope images of laser cladded substrates.
- alloy is used herein to denote a metallic composition comprising a mixture of a predominating metallic element and other elements, including impurities.
- the term “balance”, when used in reference to a particular element, is used to describe that the remainder of the composition (in wt%) excluding any alloying additions is comprised of the designated element. Hence, the total composition including the “balance” element in combination with other stated alloying elements is equal to 100 wt% of the alloy composition.
- impurity refers to a metallic or non-metallic element that is present in an alloy but which is not added intentionally. In embodiments of the present invention where only specific component elements are specified, the balance of the alloy may comprise aluminium, nickel or aluminium/nickel matrix.
- “Casting” is a manufacturing process that can produce metal components through the use of moulds.
- the mould may be sacrificial, as in the case of gravity casting where a sand-mould is used, or the mould may take the form of a reusable die, such as may be used in high pressure die casting processes.
- the casting process involves a furnace, metal and the mould.
- a casting machine may also be used to apply pressure to the mould or die during the casting process.
- the metal is first melted in the furnace and then poured or injected, optionally under pressure, into the mould. Once the casting has cooled and has set the part can be subjected to additional tooling or trimmed and finished.
- the cutting of the cast metal product is also known as machining. Casting processes can produce large and small component parts, with geometrically complex shapes. The cast parts are typically of high strength and can be subjected to considerable loads when in use. The process supports a reasonably high rate of production and is favoured producing consistent parts with good surface finish.
- Machining is a manufacturing process that can produce metal components. Machining involves various processes by which a raw material, typically metal material, is cut into a desired shape. Machining may comprise any process that removes material in a controlled manner from a work piece (subtractive manufacturing). Traditionally there are three main machining processes, namely: turning (rotation of the work piece against a cutting tool), drilling (production of holes by bringing a rotating cutter in contact with the work piece) and milling (rotation of the cutting toll to bring the cutting edges to bear against the work piece).
- “Laser cladding” (after casting) is a process that allows for the deposition of material onto a substrate. More specifically, the cladding is applied by the melting of a metallic powder by a laser beam that is focussed upon a target area for where the cladding is to be applied. The laser beam slightly melts the surface of the target area creating a weld pool. Powder is applied through a coaxial or lateral nozzle partly carried by a shielding gas. Once the powder mixes with the melt pool it is melted under the heat of the laser beam. As the laser traverses along the workpiece the cladding solidifies, cooling rapidly forming a hard facing layer on the surface of the workpiece. In order to produce the coating either the nozzle/laser assembly or substrate may be moved in X, Y and Z direction.
- vehicle is used to denote any means in or by which people, animals or goods are transported or conveyed.
- vehicles may include road transport motor vehicles as well as rail locomotives.
- Watercraft may include marine vessels, such as boats, ships, submarines and hovercraft.
- Aircraft may include fixed wing or non-fixed wing aircraft, as well as spacecraft.
- composition refers to a composition predominantly comprising metals suitable for use in laser cladding.
- the composition may be a composite material, preferably a composite powder.
- hardener refers to any material or element that improves the strength (hardness) of the overall composition, typically the cladding material. Engine tests will typically determine if the cladding material is hard enough.
- matrix material refers to the material, typically metal in which the hardener is embedded. Typically the matrix material is the predominant material in the composition.
- the matrix material may be nickel/aluminium.
- Particle form refers to a material or composition being in the form of particles such as powders or any other granular materials. Particles are typically considered small localised object having physical or chemical properties such as volume, density or mass.
- machined or cast part refers to any part produced by the processes described above i.e. machining and casting.
- depth of the cladding layer refers to the thickness of the cladding layer which has been deposited onto a substrate comprised within a work piece. This “depth” encompasses the thickness of a heat affected layer within the body of the substrate, the thickness of the layer below the surface of the work piece and the thickness of any deposition above the surface of the work piece.
- composition of a specific embodiment of the invention for use in laser cladding of a machined or cast aluminium part that comprises: a matrix material and a hardener, wherein the hardener is present in an amount of at least 1 wt% and at most about 20wt% and the balance of the composition comprising the matrix material, wherein the matrix material comprises nickel and aluminium, and wherein the hardener is chromium carbide, tungsten carbide and silicon carbide. Typically, the hardener is chromium carbide.
- the hardener is present in the composition of the herein presented invention at an amount of at least about 3wt%, or suitably about 5wt%, or typically about 7.5wt%; and suitably at most about 10wt%, or typically about 15wt%, or optionally up to about 20wt%.
- the hardener of present composition is able to increase the hardness of the composition once deposited via a laser cladding process onto a substrate.
- the substrate may be an aluminium substrate or work piece, and is typically a valve seat and/or exhaust port and/or intake surface. It is important to achieve a sufficiently hard cladding layer in order to reduce the amount of friction abrasion whilst providing for a part that is still can be machined and falls within the hardness allowed for machining.
- the present composition provides for such a composition.
- the matrix is present in the composition of the herein presented invention at an amount of at least about 80wt%, or suitably about 85wt%, or typically about 90wt%; and suitably at most about 92wt%, or typically about 95wt%, or optionally up to about 97wt%.
- the matrix material may comprise: nickel coated aluminium; aluminium coated nickel; mixtures of aluminium and nickel; or combinations thereof.
- the matrix material may be in particulate form.
- the matrix material may predominately comprise nickel.
- the matrix material may comprise at least about 80wt% nickel, typically at least about 90wt% nickel.
- the matrix material may comprise at most about 98wt% nickel, typically about 95wt% nickel.
- the matrix material comprises about 93 wt% nickel.
- the matrix material may also comprise aluminium.
- the matrix material may comprise at least about 1wt% aluminium, typically at least about 1wt% aluminium.
- the matrix material may comprise at most about 10 wt% aluminium, typically about 5wt% aluminium.
- the matrix material comprises about 4 wt% aluminium.
- the matrix material may be used as a first phase which is then supplemented by a second phase comprising a hardening material (hardener).
- a hardening material may be chromium carbide, tungsten carbide, silicon carbide or mixtures thereof.
- the hardener may be added in an amount of about 40wt%, about 25wt% or about 10wt%.
- the hardener may be present in an amount of about 5wt% or about 7.5wt%.
- composition has to comprise an adequate level of porosity and hardness whilst avoiding delamination.
- the composition may comprise an organic binder in the amount of at least about 0.1 wt% and at most about 1 5wt%. Typically, the organic binder may be present in about 0.5 wt%.
- the depth of the cladding layer applied to the valve seat may be at least about 500 microns or suitably about 750 microns, or typically about 1000 microns and suitably at most about 1500 microns, or typically about 2000 microns or optionally up to about 2500 microns.
- the depth of the cladding layer that extends above the surface of the work piece prior to applying the cladding may be at least about 50 microns, or suitably about 100 microns, or typically about 150 microns and suitably at most about 200 microns, or typically about 250 microns or optionally up to about 300 microns.
- the cladding layer applied to the valve seat surface integrates into the body of the valve seat as well as extending slightly proud of the surface.
- the maximum average particle size may be at most 500 pm. More suitably, the maximum average particle size may be at most 300pm, 250pm, 200pm, 150pm, or 100pm. Most suitably, the maximum average particle size may be at most 50pm, 40pm, 30pm, 20pm, 10pm, or 5pm. The minimum average particle size may be 0.01 pm, 0.1 pm, 0.5pm, 1 pm, 2pm, or 5pm.
- An alternative measure of particle size is to quote a maximum particle size and a percentage value or “d” value for the proportion of the sample that falls below that particle size.
- the particle size of the matrix material may be at most 500pm. More suitably, the maximum particle size may be at most 300pm, 250pm, 200pm, 150pm, or 100pm. Most suitably, the maximum particle size may be at most 50pm, 40pm, 30pm, 20pm, 10pm, or 5pm. The minimum particle size may be 0.01 pm, 0.1 pm, 0.5pm, 1 pm, 2pm, or 5pm. Any “d” value may be associated with these particle sizes.
- the “d” value associated with any of the above maximum particle sizes may be d99, d98, d95, d90, d80, d70, d60, or d50.
- the surface of the machined part may be a machined profile of a radius of at least about 2 mm and at most about 4 mm, typically 3 mm.
- the composition is used in the manufacture of a valve seat surface and/or exhaust port surface and/or intake port surface within the cylinder head of an engine. Typically the composition is applied to the surface of a profile machined on to the intake port and/or exhaust port openings and/or the valve seat via a laser cladding process. Any composition or process described herein is applicable to the surface of a valve seat and/or intake port opening and/or exhaust port opening of a cylinder.
- FIG. 1 A shows a cross section of a cylinder head having valve seat 100a with a laser cladded surface 104a in accordance with an embodiment of the present invention.
- Figure 1 B shows a cross section of a cylinder head having a traditional valve seat 100b with a valve seat insert 104b.
- valve seat 102a, 102b as part of the cylinder head 100a, 100b provides for a surface against which the exhaust valve poppet 108a, 108b rests. Therefore, it is highly desirable for the valve seat surface to be abrasion and heat resistant.
- so-called valve seat inserts 104b have been deployed via push fit into a recess formed in the cylinder head to address this problem ( Figure 1 B).
- valve seat inserts 104b occupy a lot of space around the port opening 106b in the cylinder 100b and therefore restrict available design space for optimisation of cooling.
- valve seat insert 104b is replaced by a laser clad valve seat surface 104a.
- the distance between the valve centres is reduced allowing for larger valve heads 108a.
- the cooling jacket area as well as the port geometry 106a is suitably enlarged for optimised air flow.
- the overall reduction in mass around the cylinder head is highly advantageous resulting in improved cooling as well as contributing to a lighter engine block. This in turn leads to consequent improvements in operational and manufacturing efficiency for engines and vehicles that comprise the embodiments of the invention.
- FIG. 1A there is shown a cross sectional view of an engine cylinder head as a whole 100a.
- the cylinder head is typically integrated into a cylinder block to define a combustion chamber which is not shown.
- a valve which may be a poppet valve (not shown) having a valve head 108a.
- the internal walls of the cylinder head 100a are substantially tapered towards the port opening 106a.
- a valve seat 102a upon which the valve head 108a rests when the poppet valve is closed.
- the valve seat 102 according to the present invention is provided with a nickel aluminium cladding layer 104a. Accordingly, the cylinder head is provided with an integral valve seat surface without the need for a valve seat insert part.
- FIG. 1 B there is shown the same cylinder head as described above in relation to Figure 1A. However, instead of a cladded valve seat 102a, 104a there is shown a valve seat insert 104b which has traditionally been deployed in for example the automotive industry.
- FIG. 2 there is shown electron microscope images of nickel aluminium cladding compositions 202b, 202c deposited onto aluminium substrates 208b, 208c using different beam radii and traverse speeds during the laser cladding process.
- the beam radius and traverse speeds used during the laser cladding process can have an effect on the number of voids, the porosity and level of oxidation in the cladding layer.
- each electron microscope image B and C is additionally provided below with a schematic drawing illustrating the layers visible in the electron microscope image namely: the ‘cladding layer below the valve seat surface’ 204b, 204c sandwiched between the ‘heat affected zone (HAZ)’ 206b, 206c as the bottom layer and the ‘cladding layer above the valve seat surface’ 202b, 202c as the top layer.
- HAZ heat affected zone
- a variety of hardeners in particulate form namely: chromium carbide, tungsten carbide and silicon carbide have been added in an amount of 10 wt%, 25 wt% and 40 wt% to nickel aluminium matrix material in particulate form.
- Experimental details of the laser cladding process parameters are provided in table 1 below.
- the peak hardness determined by the Vickers Hardness Test in Micro Hv has been measured for every composition. It was found that silicon carbide compositions lead to delamination of silicon carbide cladding. Although not showing delamination, tungsten carbide compositions suffered from large amounts of porosity especially for higher hardener loadings (25 wt% and 40 wt%). Similarly chromium carbide compositions having a 40wt% hardener loading showed delamination. However, the inventors of the present disclosure have surprisingly found that chromium carbide compositions at loadings of 10wt% and 25 wt% showed sufficient hardness whilst not causing delamination.
Landscapes
- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Chemical & Material Sciences (AREA)
- Materials Engineering (AREA)
- Manufacturing & Machinery (AREA)
- Metallurgy (AREA)
- Organic Chemistry (AREA)
- Composite Materials (AREA)
- General Engineering & Computer Science (AREA)
- Laser Beam Processing (AREA)
- Compositions Of Macromolecular Compounds (AREA)
Abstract
Description
Claims
Priority Applications (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
GB2315147.5A GB2620056A (en) | 2021-03-26 | 2021-03-26 | Nickel aluminium alloy compositions |
PCT/EP2021/057906 WO2022199828A1 (en) | 2021-03-26 | 2021-03-26 | Nickel aluminium alloy compositions |
Applications Claiming Priority (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
PCT/EP2021/057906 WO2022199828A1 (en) | 2021-03-26 | 2021-03-26 | Nickel aluminium alloy compositions |
Publications (1)
Publication Number | Publication Date |
---|---|
WO2022199828A1 true WO2022199828A1 (en) | 2022-09-29 |
Family
ID=75302574
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
PCT/EP2021/057906 WO2022199828A1 (en) | 2021-03-26 | 2021-03-26 | Nickel aluminium alloy compositions |
Country Status (2)
Country | Link |
---|---|
GB (1) | GB2620056A (en) |
WO (1) | WO2022199828A1 (en) |
Citations (5)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US3285235A (en) | 1964-12-24 | 1966-11-15 | Gen Electric | Valve seat insert |
US4723518A (en) | 1985-12-25 | 1988-02-09 | Toyota Jidosha Kabushiki Kaisha | Aluminum alloy cylinder head with valve seat formed integrally by copper alloy cladding layer and underlying alloy layer |
KR20040009306A (en) * | 2002-07-23 | 2004-01-31 | 현대자동차주식회사 | Ni-Cr based metal powder composition for laser cladding and preparation method for valve sheet by using them |
WO2016146735A1 (en) * | 2015-03-19 | 2016-09-22 | Höganäs Ab (Publ) | New powder composition and use thereof |
CN104532231B (en) * | 2014-12-25 | 2017-08-22 | 中国钢研科技集团有限公司 | The method that Ni3Al/Cr3C2 composite coatings are prepared using laser melting and coating technique |
-
2021
- 2021-03-26 GB GB2315147.5A patent/GB2620056A/en active Pending
- 2021-03-26 WO PCT/EP2021/057906 patent/WO2022199828A1/en active Application Filing
Patent Citations (5)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US3285235A (en) | 1964-12-24 | 1966-11-15 | Gen Electric | Valve seat insert |
US4723518A (en) | 1985-12-25 | 1988-02-09 | Toyota Jidosha Kabushiki Kaisha | Aluminum alloy cylinder head with valve seat formed integrally by copper alloy cladding layer and underlying alloy layer |
KR20040009306A (en) * | 2002-07-23 | 2004-01-31 | 현대자동차주식회사 | Ni-Cr based metal powder composition for laser cladding and preparation method for valve sheet by using them |
CN104532231B (en) * | 2014-12-25 | 2017-08-22 | 中国钢研科技集团有限公司 | The method that Ni3Al/Cr3C2 composite coatings are prepared using laser melting and coating technique |
WO2016146735A1 (en) * | 2015-03-19 | 2016-09-22 | Höganäs Ab (Publ) | New powder composition and use thereof |
Non-Patent Citations (1)
Title |
---|
SALLAMAND P ET AL: "Laser cladding on aluminium-base alloys: microstructural features", MATERIALS SCIENCE, ELSEVIER, AMSTERDAM, NL, vol. 171, no. 1-2, 1 November 1993 (1993-11-01), pages 263 - 270, XP024167338, ISSN: 0921-5093, [retrieved on 19931101], DOI: 10.1016/0921-5093(93)90414-A * |
Also Published As
Publication number | Publication date |
---|---|
GB202315147D0 (en) | 2023-11-15 |
GB2620056A (en) | 2023-12-27 |
Similar Documents
Publication | Publication Date | Title |
---|---|---|
DE102017200945B3 (en) | Method for producing hybrid lightweight brake discs | |
KR100304479B1 (en) | Coatings consisting of microporous aluminum / silicon alloys | |
JP5680859B2 (en) | Method for manufacturing a nozzle for a fuel valve of a diesel engine and nozzle | |
US7541561B2 (en) | Process of microwave heating of powder materials | |
EA001332B1 (en) | Sintered mechanical part with abrasionproof surface and method for producing same | |
US20020165634A1 (en) | Fabrication of laminate tooling using closed-loop direct metal deposition | |
EP3446813B1 (en) | Method of tailoring high strength aluminum alloys for additive manufacturing through the use of grain refiners | |
JP7018603B2 (en) | Manufacturing method of clad layer | |
US20200040840A1 (en) | Coated valve seat region of an internal combustion engine | |
JP3835694B2 (en) | Manufacturing method of valve seat | |
Bidare et al. | Porosity, cracks, and mechanical properties of additively manufactured tooling alloys: a review | |
JP4208836B2 (en) | A nozzle for a fuel valve in a diesel engine and a method of manufacturing the nozzle. | |
CN109290573B (en) | Method for manufacturing aluminum-copper composite part by laser additive manufacturing | |
WO2018157159A1 (en) | Aluminum alloy compositions, products and methods of making the same | |
Lu et al. | Comparison of wire-arc and powder-laser additive manufacturing for IN718 superalloy: unified consideration for selecting process parameters based on volumetric energy density | |
US20190345615A1 (en) | Laser deposition processes for coating articles | |
Motwani et al. | Mechanical characteristics and microstructural investigation of CMT deposited bimetallic SS316LSi-IN625 thin wall for WAAM | |
WO2022199828A1 (en) | Nickel aluminium alloy compositions | |
EP2140042B1 (en) | Production of a partial fiber composite structure in a component using a laser remelting treatment | |
JPS62270277A (en) | Production of titanium base alloy-made wear resistant member | |
US7431881B2 (en) | Wear-resistant alloys particularly suited to aluminum-engine head-valve seats | |
US20220001447A1 (en) | Method for modifying the dimensions of a cast iron pump part | |
US20160296997A1 (en) | Die-casting system with a refractory metal alloy surface | |
US20160311015A1 (en) | Die-casting system with enhanced adherence shot sleeve pour liner | |
JPH11256306A (en) | Spray forming method of insert |
Legal Events
Date | Code | Title | Description |
---|---|---|---|
121 | Ep: the epo has been informed by wipo that ep was designated in this application |
Ref document number: 21715563 Country of ref document: EP Kind code of ref document: A1 |
|
ENP | Entry into the national phase |
Ref document number: 202315147 Country of ref document: GB Kind code of ref document: A Free format text: PCT FILING DATE = 20210326 |
|
NENP | Non-entry into the national phase |
Ref country code: DE |
|
122 | Ep: pct application non-entry in european phase |
Ref document number: 21715563 Country of ref document: EP Kind code of ref document: A1 |