EP0640759A1 - Composant de construction moulé en aluminium renforcé partiellement et procédé de fabrication - Google Patents

Composant de construction moulé en aluminium renforcé partiellement et procédé de fabrication Download PDF

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Publication number
EP0640759A1
EP0640759A1 EP94112615A EP94112615A EP0640759A1 EP 0640759 A1 EP0640759 A1 EP 0640759A1 EP 94112615 A EP94112615 A EP 94112615A EP 94112615 A EP94112615 A EP 94112615A EP 0640759 A1 EP0640759 A1 EP 0640759A1
Authority
EP
European Patent Office
Prior art keywords
reinforcing element
casting
spray
cast
component
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Granted
Application number
EP94112615A
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German (de)
English (en)
Other versions
EP0640759B1 (fr
Inventor
Rolf Dipl.-Ing. Schattevoy
Klaus Dipl.-Phys. Hummert
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
WKW AG
Original Assignee
Peak Werkstoff GmbH
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 Peak Werkstoff GmbH filed Critical Peak Werkstoff GmbH
Publication of EP0640759A1 publication Critical patent/EP0640759A1/fr
Application granted granted Critical
Publication of EP0640759B1 publication Critical patent/EP0640759B1/fr
Anticipated expiration legal-status Critical
Expired - Lifetime legal-status Critical Current

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D19/00—Casting in, on, or around objects which form part of the product
    • B22D19/0009—Cylinders, pistons
    • B22D19/0027—Cylinders, pistons pistons
    • 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
    • C23C4/123—Spraying molten metal
    • 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 
    • 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
    • F02F—CYLINDERS, PISTONS OR CASINGS, FOR COMBUSTION ENGINES; ARRANGEMENTS OF SEALINGS IN COMBUSTION ENGINES
    • F02F2200/00—Manufacturing
    • F02F2200/04—Forging of engine parts
    • 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
    • F05C2201/02—Light metals
    • F05C2201/021—Aluminium
    • 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
    • F05C2201/02—Light metals
    • F05C2201/028—Magnesium
    • 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
    • F05C2201/0433—Iron group; Ferrous alloys, e.g. steel
    • F05C2201/0448—Steel
    • 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
    • F05C2253/00—Other material characteristics; Treatment of material
    • F05C2253/16—Fibres

Definitions

  • the invention relates to a partially reinforced Al cast component, consisting of an Al cast part and a reinforcing part, at least partially encased by the base material thereof, and the method for producing such reinforced Al cast components.
  • Complicated workpieces such as. B. inexpensive manufacture of pistons for internal combustion engines, cylinder heads or engine blocks.
  • Such components in particular certain areas of these components, are subject to high thermal and / or mechanical loads when subjected to operating stress.
  • unfavorable constructions with large wall thicknesses are often required or difficult-to-cast aluminum alloys have to be used.
  • Such alloys are e.g. B. hypereutectic AlSi cast alloys, which are used to increase the necessary wear resistance and thermal conductivity of cylinder liners.
  • these alloys can only be cast with great effort and in small series.
  • the wear resistance of the tread is achieved by means of special etching and coating processes, which are also justifiable on a small scale with regard to their environmental impact and the disposal of the chemicals that are produced.
  • Another disadvantage of such a method is the complex finishing, which is only possible with diamond tools, and if fibers are cut during machining, these can separate from the matrix over time and lead to damage to the components that come into contact with the fibers .
  • Friction welding is, however, limited to simple component geometries, since only axial and no radial welding is possible. In addition, there is the risk that the friction welding creates stresses in the component, which make additional heat treatment necessary for relaxation. Another disadvantage of this method is the number of method steps. Friction welding itself is an additional step, and in order to achieve reproducible results, both the reinforcing part and the cast workpiece must be machined before welding.
  • DE-PS 31 00 755 describes a component which has an insert made of dispersion-hardened sintered aluminum, which is introduced into the component by pouring, pressing or welding. Pouring as a manufacturing process of reinforced Al castings is inexpensive, since no additional process step, such as. B. in friction welding, is necessary to produce the composite.
  • a disadvantage of the component proposed in DE-PS 31 00 755 is that no perfect connection is achieved in the joining zone. Due to the high gas content of the powder-metallurgically manufactured materials, they are not very suitable for pouring. When contacting a powder metallurgical component, which either consists of an Al sintered material (powder metallurgical molding process) or a PM material (powder metallurgical semi-finished process), which, for. B.
  • a component is made available, consisting of an aluminum casting and a reinforcing part, at least partially encapsulated by its base material, which consists of a spray-compacted aluminum material.
  • Spray compacting and the further process steps of extrusion or forging can be used to produce aluminum profiles or aluminum forgings that are far superior in their properties to conventional cast aluminum alloys.
  • These Al materials have significantly lower gas contents than the Al sintered materials or PM-Al materials, which are even lower than the gas contents of conventional cast aluminum or wrought aluminum alloys.
  • this process can be used to produce materials that are similar in mechanical and physical properties to the Al-PM materials produced by spraying.
  • the spray compacting method makes it possible to increase the Si content in the Al material to over 35% by weight Si without any problems.
  • This makes it possible to set the coefficient of thermal expansion to any value between 23 ⁇ 10 ⁇ 6K ⁇ 1 and 13 ⁇ 10 ⁇ 6K ⁇ 1.
  • the content of other alloying elements such as Fe, Ni, Cu, Mg can be set within wide limits for technically meaningful and usable alloys, it is very easy to set materials precisely for a given application.
  • the low gas contents enable these materials to be poured in without the formation of pores, which enables technically sensible and inexpensive composite components.
  • Such composite components are produced by positioning the reinforcing component, for example an extruded section, a forging or a component produced using a machining process, from a spray-compacted Al alloy at the point in the casting mold where reinforcement is to take place in the finished casting workpiece.
  • the reinforcement component is preheated. With the choice of the preheating temperature, the degree of melting can be adjusted so that the reinforcing component is also complete is melted and this results in complete mixing with the casting material in the area of the reinforcement, as a result of which the latter is partially alloyed on.
  • melt flows around the reinforcement component in parallel and at a sufficiently high speed as a result of which the oxide layer which is always present on aluminum is washed off and there is direct contact of the Al melt with the oxide-free Al surface is coming.
  • This washing process can be achieved either by skillful choice of the sprue points, by stirring, by generating eddy currents with the aid of induction coils, or similar means which produce a flow of the melt parallel to the surface of the reinforcing component during or directly after the casting.
  • Example 1 Comparison of the composite according to the invention with a composite made of PM-Al material and cast aluminum.
  • Example 2 Application of the composite according to the invention to pistons for internal combustion engines.
  • Pistons for internal combustion engines are an example of an application for partial reinforcement with the aid of casting. Upper piston parts are shown in FIGS. 4a and 4b. Figure 5 shows the schematic representation of the piston crown.
  • Pistons 1 are today mostly made of Si-containing eutectic or hypereutectic cast alloys. Particularly in the case of pistons for direct injection diesel engines that are subjected to high loads, the bowl rim zone 4 is exposed to high temperatures and mechanical loads. In the areas of the piston skirt 5, aluminum cast materials 2 meet the requirements there. By pouring spray-compacted aluminum alloys (e.g. AlSi20Fe5Ni2) into the stressed areas, the bowl rim zone 4 or the entire combustion chamber bowl 7 can be inexpensively strengthened 3, which makes it possible to design the piston 1 with which more effective combustion can be achieved. Further reinforcement options on piston 1 are e.g. the area of the ring groove 6, where some iron-based materials are already poured in to minimize wear due to the movement of the piston rings.
  • spray-compacted aluminum alloys e.g. AlSi20Fe5Ni2
  • a further reinforcement according to the invention can be provided in the area of the top land (see Figure 5).
  • the use of spray-compacted high-performance aluminum at these points results in considerable improvements due to the perfect combination of the casting alloy 2 with the reinforcements 3. It is thereby possible to minimize the distance between the uppermost piston ring and the piston crown 9, which leads to reduced pollutant values.
  • Example 3 Application of the composite according to the invention to cylinder heads of internal combustion engines.
  • Another example is the reinforcement of cylinder heads of internal combustion engines to the combustion chamber side. Due to the resulting high temperatures and the formation of a temperature gradient, tensions occur in the cylinder head, which usually lead to cracks in the area of the webs between the valves. If a reinforcement is carried out in these areas with a material that on the one hand withstands the thermal and mechanical loads better, and on the other hand has a different coefficient of thermal expansion than the cast alloy of the cylinder head, which has to be used because of the complexity and the mold filling capacity, the tension can induced by the temperature gradient, do not reach critical values for crack formation.
  • Example 4 Application of the composite according to the invention in cylinder liners of internal combustion engines

Landscapes

  • Engineering & Computer Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Mechanical Engineering (AREA)
  • Combustion & Propulsion (AREA)
  • General Engineering & Computer Science (AREA)
  • Plasma & Fusion (AREA)
  • Physics & Mathematics (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Materials Engineering (AREA)
  • Metallurgy (AREA)
  • Organic Chemistry (AREA)
  • Manufacture Of Alloys Or Alloy Compounds (AREA)
  • Forging (AREA)
EP94112615A 1993-08-26 1994-08-12 Composant de construction moulé en aluminium renforcé partiellement et procédé de fabrication Expired - Lifetime EP0640759B1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
DE4328619A DE4328619C2 (de) 1993-08-26 1993-08-26 Partiell verstärktes Al-Gußbauteil und Verfahren zu dessen Herstellung
DE4328619 1993-08-26

Publications (2)

Publication Number Publication Date
EP0640759A1 true EP0640759A1 (fr) 1995-03-01
EP0640759B1 EP0640759B1 (fr) 1997-03-05

Family

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EP94112615A Expired - Lifetime EP0640759B1 (fr) 1993-08-26 1994-08-12 Composant de construction moulé en aluminium renforcé partiellement et procédé de fabrication

Country Status (4)

Country Link
EP (1) EP0640759B1 (fr)
AT (1) ATE149637T1 (fr)
DE (1) DE4328619C2 (fr)
ES (1) ES2098085T3 (fr)

Cited By (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP0807750A1 (fr) * 1996-05-16 1997-11-19 Zollner Corporation Piston moulé avec une chambre de combustion avec un bord renforcé
WO1997048895A1 (fr) * 1996-06-14 1997-12-24 Metal Leve S.A. Indústria E Comércio Piston pour moteur a explosion
FR2849899A1 (fr) * 2003-01-14 2004-07-16 Renault Sa Piston comportant un insert en alliage d'aluminium et procede pour sa fabrication
WO2012065661A1 (fr) * 2010-11-17 2012-05-24 Daimler Ag Piston à canal de refroidissement et procédé de fabrication dudit piston à canal de refroidissement
WO2013144072A1 (fr) * 2012-03-28 2013-10-03 Mahle International Gmbh Procédé de fabrication d'un piston en aluminium

Families Citing this family (18)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE19634504A1 (de) 1996-08-27 1997-12-04 Daimler Benz Ag In ein Leichtmetall-Gußteil einzugießender Rohling eines anderen Leichtmetallteiles und Verfahren zum Herstellen eines solchen Rohlinges
DE19712624C2 (de) * 1997-03-26 1999-11-04 Vaw Motor Gmbh Aluminiummatrix-Verbundwerkstoff und Verfahren zu seiner Herstellung
DE19733204B4 (de) 1997-08-01 2005-06-09 Daimlerchrysler Ag Beschichtung aus einer übereutektischen Aluminium/Silizium Legierung, Spritzpulver zu deren Herstellung sowie deren Verwendung
DE19733205B4 (de) * 1997-08-01 2005-06-09 Daimlerchrysler Ag Beschichtung für eine Zylinderlauffläche einer Hubkolbenmaschine aus einer übereutektischen Aluminium/Siliziumlegierung, Spritzpulver zu deren Herstellung und deren Verwendung
DE19748144C2 (de) * 1997-10-31 2000-04-27 Daimler Chrysler Ag Verfahren zur Herstellung von Basiskörpern aus Metallspänen
DE19836706B4 (de) * 1998-04-17 2008-11-20 Audi Ag In ein Aluminium-Gußteil einzugießender Grauguß-Rohling und entsprechendes Gußverfahren
DE10012787B4 (de) * 2000-03-16 2008-04-10 Volkswagen Ag Verfahren zur Herstellung von Leichtmetallgussteilen mit eingegossenen Buchsen
DE10129046B4 (de) * 2001-06-15 2006-01-05 Ks Kolbenschmidt Gmbh Kolben für eine Brennkraftmaschine mit einem Eingußkörper
DE10235911B3 (de) * 2002-08-06 2004-04-15 Peak-Werkstoff Gmbh Gussverbund von Hohlprofilen aus Leichtmetall-Legierung und Verfahren zu seiner Herstellung
DE10316002B3 (de) * 2003-04-08 2004-10-28 Federal-Mogul Nürnberg GmbH Verfahren zur Herstellung eines Kolbens für einen Verbrennungsmotor
DE10353473B4 (de) * 2003-11-15 2007-02-22 Daimlerchrysler Ag Bauteil einer Brennkraftmaschine und Verfahren zu dessen Herstellung
DE102004029070B4 (de) * 2004-06-16 2009-03-12 Daimler Ag Verfahren zum Eingießen eines Rohlings aus Eisenlegierung in ein Aluminium-Gussteil
DE102005042857A1 (de) 2005-09-08 2007-03-22 Ks Kolbenschmidt Gmbh Kolben für eine Brennkraftmaschine
DE102005061060A1 (de) * 2005-12-21 2007-06-28 Mahle International Gmbh Kolben für einen Verbrennungsmotor und Verfahren zu seiner Herstellung
DE102007052498A1 (de) * 2007-11-02 2009-05-07 Mahle International Gmbh Verfahren zum Herstellen eines Kolbens für einen Verbrennungsmotor, mit diesem Verfahren herstellbarer Kolben sowie Vorrichtung zur Durchführung des Verfahrens
DE102012208860A1 (de) * 2012-05-25 2013-11-28 Peak-Werkstoff Gmbh Verfahren zur Herstellung von Kolbenringen
DE102012104820B4 (de) * 2012-06-04 2014-10-09 Actech Gmbh Verfahren zur Herstellung von Verbundgussteilen
DE102021112326A1 (de) 2021-05-11 2022-11-17 Volkswagen Aktiengesellschaft Zylindergehäuse und Motorblock für einen Verbrennungsmotor

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JPS56166368A (en) * 1980-05-22 1981-12-21 Toyota Motor Corp Sliding member
JPS59231163A (ja) * 1983-06-13 1984-12-25 Yamaha Motor Co Ltd 内燃機関のシリンダヘツド
DE3518058A1 (de) * 1984-06-01 1985-12-05 Kanthal Ab, Hallstahammar Kolben fuer verbrennungsmotoren
EP0262869A1 (fr) * 1986-09-24 1988-04-06 Alcan International Limited Poudre composite en alliage d'aluminium
DE4010474A1 (de) * 1990-03-31 1991-10-02 Kolbenschmidt Ag Leichtmetallkolben

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DE3100755A1 (de) * 1981-01-13 1982-09-02 Klöckner-Humboldt-Deutz AG, 5000 Köln Zylinderkopf fuer eine brennkraftmaschine
DD222930A1 (de) * 1983-12-19 1985-05-29 Druckguss & Kolbenwerke Veb Verschleissfester leichtmetallkolben und verfahren zu seiner herstellung
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JPH0636984B2 (ja) * 1990-04-27 1994-05-18 東海カーボン株式会社 部分的複合部材の製造方法
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Publication number Priority date Publication date Assignee Title
JPS56166368A (en) * 1980-05-22 1981-12-21 Toyota Motor Corp Sliding member
JPS59231163A (ja) * 1983-06-13 1984-12-25 Yamaha Motor Co Ltd 内燃機関のシリンダヘツド
DE3518058A1 (de) * 1984-06-01 1985-12-05 Kanthal Ab, Hallstahammar Kolben fuer verbrennungsmotoren
EP0262869A1 (fr) * 1986-09-24 1988-04-06 Alcan International Limited Poudre composite en alliage d'aluminium
DE4010474A1 (de) * 1990-03-31 1991-10-02 Kolbenschmidt Ag Leichtmetallkolben

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PATENT ABSTRACTS OF JAPAN vol. 9, no. 111 (M - 379)<1834> 15 May 1985 (1985-05-15) *

Cited By (10)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP0807750A1 (fr) * 1996-05-16 1997-11-19 Zollner Corporation Piston moulé avec une chambre de combustion avec un bord renforcé
WO1997048895A1 (fr) * 1996-06-14 1997-12-24 Metal Leve S.A. Indústria E Comércio Piston pour moteur a explosion
US6112715A (en) * 1996-06-14 2000-09-05 Metal Leve S.A. Industria E. Comercio Piston for an internal combustion engine
FR2849899A1 (fr) * 2003-01-14 2004-07-16 Renault Sa Piston comportant un insert en alliage d'aluminium et procede pour sa fabrication
EP1439301A1 (fr) * 2003-01-14 2004-07-21 Renault s.a.s. Piston comportant un insert en alliage d'aluminium et procédé pour sa fabrication
WO2012065661A1 (fr) * 2010-11-17 2012-05-24 Daimler Ag Piston à canal de refroidissement et procédé de fabrication dudit piston à canal de refroidissement
US9429100B2 (en) 2010-11-17 2016-08-30 Daimler Ag Cooling duct piston and method for producing the same
WO2013144072A1 (fr) * 2012-03-28 2013-10-03 Mahle International Gmbh Procédé de fabrication d'un piston en aluminium
CN104185529A (zh) * 2012-03-28 2014-12-03 马勒国际有限公司 用于生产铝活塞的方法
CN104185529B (zh) * 2012-03-28 2017-03-01 马勒国际有限公司 用于生产铝活塞的方法

Also Published As

Publication number Publication date
EP0640759B1 (fr) 1997-03-05
ATE149637T1 (de) 1997-03-15
DE4328619C2 (de) 1995-08-10
ES2098085T3 (es) 1997-04-16
DE4328619A1 (de) 1995-03-02

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