CN105925939B - 一种氮化钛纳米双层涂层发动机气缸套的制备工艺 - Google Patents
一种氮化钛纳米双层涂层发动机气缸套的制备工艺 Download PDFInfo
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Abstract
本发明属于材料涂层领域和汽车发动机制造技术领域,特别涉及一种超耐磨的氮化钛纳米双层涂层发动机缸套制备工艺。利用本发明的制备工艺制作的氮化钛纳米双层涂层发动机气缸套,含有高硬度氮化钛涂层和韧性金属钛,可以在保持较高硬度的同时提高涂层的韧性与气缸体间的结合强度,从而提高涂层的耐磨性,这种纳米双层涂层结构,可以有效弥补氮化钛单涂层韧性较差的不足,显著减小气缸体的磨损,延长发动机的使用寿命,该纳米双层涂层气缸套制备工艺容易掌握,生产过程稳定可靠。
Description
技术领域
本发明属于材料涂层领域和汽车发动机制造技术领域,特别涉及一种超耐磨的氮化钛纳米双层涂层发动机缸套制备工艺。
背景技术
汽车发动机为汽车提供动力,是汽车的心脏,影响汽车的动力性、经济性和环保性。汽车发动机大多是热能动力装置,借助工质的状态变化将燃料燃烧产生的热能转变为机械能。汽车发动机气缸是组成燃烧室的重要零件,其工作环境恶劣,是发动机上较易损伤的零件之一。气缸套安装在气缸体的缸筒内,与活塞和缸盖共同组成燃烧室。气缸套内表面不但与高温高压燃气接触,还与进气过程的冷空气接触,工作过程温度变化剧烈,润滑条件很差,工作条件较为恶劣,活塞的往复运动又会造成缸壁的过度磨损、工作面易被拉伤等问题。气缸套的损伤既影响了发动机工作质量和效率,也决定着发动机的使用寿命。
发明内容
本发明的目的就是要解决发动机气缸套可靠性能差、不耐磨、寿命低等问题,提供一种超耐磨的氮化钛纳米双层涂层发动机缸套制备工艺,提高气缸套的可靠性、耐磨性。与现有技术相比,本案工艺具有制造工艺简单特点,使气缸套的硬度更高,韧性更好,经久耐磨,可有效地提升发动机的工作性能。
本发明通过以下方式实现:
一种氮化钛纳米双层涂层发动机气缸套的制备工艺,发动机气缸套材料为20钢,双层涂层分别为纳米钛和氮化钛,依次沉积在发动机气缸套的内表面上,具体工艺步骤如下:
(1)准备阶段:将发动机气缸套装入专用夹具1内,安装固定;
(2)前处理阶段:抛光发动机气缸套内表面,然后放入酒精中,超声波清洗25min,再放入丙酮中,超声波清洗25min,烘箱烘干后,放入镀膜机中,抽真空至5.5×10-3Pa,加热至300℃,保温15~25min;
(3)离子清洗阶段:通氩气,其压力为1.0~1.5Pa线性渐变,开启偏压电源,电压750V,占空比0.3,辉光放电清洗45min;降低偏压至500V,占空比0.3,开启离子源离子清洗30min,开启钛靶电弧源,偏压450V,靶电流60A,离子轰击钛靶7min;
(4)沉积厚度为500~700nm 的钛过渡层阶段:调整氩气气压0.4~0.5Pa,偏压降至300V,沉积温度300℃,钛靶电流70A,电弧镀钛过渡层20min;
(5)沉积厚度为600~700nm 的氮化钛阶段:氩气气压0.6Pa,偏压220V,沉积温度350℃,电弧镀氮化钛层35min;
(6)后处理阶段:关闭各电源,离子源,将炉体冷却至100℃后,关闭氩气,专用夹具1、发动机气缸套随炉冷却至室温出炉;将发动机气缸套从专用夹具1中取出,去毛刺,涂层结束;
(7)检测阶段:表面精度检查、硬度抽查及金相抽查分析。
通过上述工艺制备的氮化钛纳米双层涂层发动机气缸套,含有双层涂层:高硬度氮化钛涂层和韧性金属钛,从而达到提升气缸套内表面硬度、减小残余应力,增加涂层与气缸套间的结合强度目的。该纳米双层涂层气缸套制备工艺容易掌握,生产过程稳定可靠。
附图说明
图1——一种氮化钛纳米双层涂层发动机气缸套的制备工艺专用夹具示意图。
图2——氮化钛纳米双层涂层发动机气缸套示意图。
具体实施方式
下面给出本发明的实施例,用来进一步说明技术解决方案。
实施例1,参考图1、图2。一种氮化钛纳米双层涂层发动机气缸套的制备工艺,发动机气缸套2材料为20钢,涂层3为纳米钛和氮化钛,即发动机气缸套内表面2-1上为一层钛过渡层3-1,钛过渡层3-1上为氮化钛高硬度涂层3-2,具体工艺步骤如下:
(1)准备阶段:将发动机气缸套2装入专用夹具1内,安装固定。专用夹具1由上盖1-1、上垫片1-2、石棉垫1-3、夹紧机构1-4、下筒体1-5、下垫片1-6组成;其中夹紧机构1-4又由下夹紧杆1-4-1、铰链销1-4-2、上夹紧杆1-4-3、拉紧弹簧1-4-4组成。先将上垫片1-2安装在上盖1-1的圆孔内,将下垫片1-6安装在下筒体1-5的底部圆孔内,再将发动机气缸套2装入下筒体1-5,然后在下筒体1-5上部的环形槽内安放石棉垫1-3,盖上上盖1-1,用4~10个夹紧机构1-4夹紧上盖1-1和下筒体1-5;
(2)前处理阶段:抛光发动机气缸套2内表面,去除表面油污、锈迹等杂质,然后依次放入酒精和丙酮中,超声波清洗各25min,去除发动机气缸套2内表面上的油污和附着物,烘箱烘干后,迅速放入镀膜机,抽真空至5.5×10-3Pa,加热至300℃,保温15~25min;
(3)离子清洗阶段:通氩气,其压力为1.0~1.5Pa,开启偏压电源,电压750V,占空比0.3,辉光放电清洗45min;降低偏压至500V,占空比0.3,开启离子源离子清洗30min,开启钛靶电弧源,偏压450V,靶电流60A,离子轰击钛靶7min;
(4)沉积厚度为500~700nm 的钛过渡层阶段:调整氩气气压0.4~0.5Pa,偏压降至300V,沉积温度300℃,钛靶电流70A,电弧镀钛过渡层20min;
(5)沉积厚度为600~700nm 的氮化钛阶段:氩气气压0.6Pa,偏压220V,沉积温度350℃,电弧镀氮化钛层35min;
(6)后处理阶段:关闭各电源,离子源,将炉体冷却至100℃后,关闭氩气,专用夹具1、发动机气缸套2随炉冷却至室温出炉;将发动机气缸套2从专用夹具1取出,去毛刺,涂层结束;
(7)检测阶段:表面精度检查、硬度抽查及金相抽查分析。
通过上述工艺制备的氮化钛纳米双层涂层发动机气缸套,为保证只给气缸套内表面沉积上硬化层,特别设计了专用夹具1。专用夹具1使用一段时间后,为避免因夹具表面被沉积上过厚的涂层,进而影响到发动机气缸套2的涂层沉积效果,可以随时更换上新的垫片1-2、石棉垫1-3、下垫片1-6,以延长专用夹具1的使用寿命。
Claims (1)
1.一种氮化钛纳米双层涂层发动机气缸套的制备工艺,发动机气缸套材料为20钢,双层涂层分别为纳米钛和氮化钛,依次沉积在发动机气缸套的内表面上,其特征在于,具体工艺步骤如下:
(1)准备阶段:将发动机气缸套装入专用夹具(1)内,安装固定;所述的专用夹具(1)由上盖(1-1)、上垫片(1-2)、石棉垫(1-3)、夹紧机构(1-4)、下筒体(1-5)、下垫片(1-6)组成;其中夹紧机构(1-4)又由下夹紧杆(1-4-1)、铰链销(1-4-2)、上夹紧杆(1-4-3)、拉紧弹簧(1-4-4)组成;先将上垫片(1-2)安装在上盖(1-1)的圆孔内,将下垫片(1-6)安装在下筒体(1-5)的底部圆孔内,再将发动机气缸套(2)装入下筒体(1-5),然后在下筒体(1-5)上部的环形槽内安放石棉垫(1-3),盖上上盖(1-1),用4~10个夹紧机构(1-4)夹紧上盖(1-1)和下筒体(1-5);
(2)前处理阶段:抛光发动机气缸套内表面,然后放入酒精中,超声波清洗25min,再放入丙酮中,超声波清洗25min,烘箱烘干后,放入镀膜机中,抽真空至5.5×10-3 Pa,加热至300℃,保温15~25min;
(3)离子清洗阶段:通氩气,其压力为1.0~1.5Pa线性渐变,开启偏压电源,电压750V,占空比0.3,辉光放电清洗45min;降低偏压至500V,占空比0.3,开启离子源离子清洗30min,开启钛靶电弧源,偏压450V,靶电流60A,离子轰击钛靶7min;
(4)沉积厚度为500~700nm的钛过渡层阶段:调整氩气气压0.4~0.5Pa,偏压降至300V,沉积温度300℃,钛靶电流70A,电弧镀钛过渡层20min;
(5)沉积厚度为600~700nm的氮化钛阶段:氩气气压0.6Pa,偏压220V,沉积温度350℃,电弧镀氮化钛层35min;
(6)后处理阶段:关闭各电源,离子源,将炉体冷却至100℃后,关闭氩气,专用夹具(1)、发动机气缸套随炉冷却至室温出炉,涂层结束;
(7)检测阶段:表面精度检查、硬度抽查及金相抽查分析。
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