EP1297195A1 - Oberflächenbeschichte motorkomponente und herstellungsverfahren dafür - Google Patents

Oberflächenbeschichte motorkomponente und herstellungsverfahren dafür

Info

Publication number
EP1297195A1
EP1297195A1 EP00946571A EP00946571A EP1297195A1 EP 1297195 A1 EP1297195 A1 EP 1297195A1 EP 00946571 A EP00946571 A EP 00946571A EP 00946571 A EP00946571 A EP 00946571A EP 1297195 A1 EP1297195 A1 EP 1297195A1
Authority
EP
European Patent Office
Prior art keywords
metallic layer
machining
engine component
mmc
metal
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.)
Withdrawn
Application number
EP00946571A
Other languages
English (en)
French (fr)
Inventor
Kent Strand
Sven- Ke Karlsson
Stefan Ekblad
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.)
MX Composites AB
Original Assignee
Saab AB
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 Saab AB filed Critical Saab AB
Publication of EP1297195A1 publication Critical patent/EP1297195A1/de
Withdrawn legal-status Critical Current

Links

Classifications

    • CCHEMISTRY; METALLURGY
    • C23COATING 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
    • C23CCOATING 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
    • C23C4/00Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge

Definitions

  • This invention concerns engine components made of MMC materials (Metal-matrix composite), where the component surfaces that have rotational contact or sliding contact with other engine components are coated with a friction-reducing tribologically functional material by means of a surface treatment process.
  • MMC materials Metal-matrix composite
  • connecting rods comprise the components wherein reduced mass has the most obvious beneficial effect in engines that run at relatively high speeds (above 5000 rpm). This applies in particular to the weight of the small end of the connecting rod.
  • Light materials such as aluminum, titanium or carbon fiber composite are used instead of steel in components such as connecting rods in advanced racing contexts.
  • One decisive property of the material used in connecting rods is its specific stiffness, E/p.
  • MMC material is proposed in the invention described below.
  • Structural materials of the type known collectively as MMC materials, ("metall-matris-kompositer" in Swedish) became known during the 1990s.
  • MMC materials are composites that consist of a binding material in the form of a metal such as aluminum, magnesium, titanium or alloys thereof that is reinforced through the admixture of fibers or particles in the form of ceramic substances such as silicon carbide, boron carbide or aluminum oxide.
  • MMC materials exhibit extremely interesting properties, which can be further adapted depending on the area of application, thus offering advantages in that the component can be made lighter, stronger, stiffer and possessed of better fatigue properties than can be achieved using conventional materials within the specific area of application in question.
  • MMC materials are very difficult to machine.
  • To create a component made of MMC material methods are usually used in which the component is cast in a shape that is closely akin to the final shape of the component.
  • Another method involves using a forged billet or a piece of extruded bar, so that spark machining of the surface and conventional cutting techniques can be used to produce the final component shape.
  • Attempts have been made to produce e.g. connecting rods for motorcycles by means of such conventional fabricating and machining methods. In this way, the goal of achieving the desired component and its desired properties, such as lower weight, has been achieved, and the use of such connecting rods in an engine results in an engine that turns more readily and vibrates less.
  • the problem is that the cost of producing engine components by conventional means has been extremely high, thereby limiting use to areas where cost is of lesser importance.
  • Patent application PCT/SE/02007 which was not yet published at the time of the submission of the present application, presents a method that shows that MMC materials can be machined by HSM (High-Speed Machining), and this method was used in the fabrication of products related to the present invention. Everything described in patent application PCT/SE/02007 is hereby incorporated into the present patent application.
  • One aspect of the present invention concerns engine components made of an MMC material (Metal-matrix composite) provided with a surface treatment in the form of an applied tribologically functional layer on surfaces that are subject to abrasive friction through contact with rotating or sliding elements.
  • the applied layer preferably consists of a thin, easy-to-work metallic layer of, e.g. a bronze.
  • a method for surface treating an engine component made of MMC material, wherein surfaces of the component that are subject to abrasive friction are coated with a metallic layer.
  • the applied layer is preferably applied by spraying.
  • Yet another aspect of the invention comprises a method for fabricating an engine component with surface treatment of designated surfaces of the component wherein, in a first step, the component is machined by cutting via high-speed machining of a raw billet of MMC material.
  • HSM high-speed machining
  • the reinforcement phase in the MMC material consists of ceramic particles, which are commonly used as abrasives, these particles can have a wearing effect on materials in affected surfaces on adjacent engine elements.
  • the layer applied on the MMC component in accordance with the invention prevents such wear against other engine elements.
  • a first example of an application of the invention is based on the fact the MMC materials make possible an optimized connecting rod design achieved by choosing the materials and geometrical configuration used based on the set requirements for the engine application in question, i.e. whether the engine is intended for, e.g. a motorcycle, car, race car, boat, truck, work machine, etc.
  • Connecting rods made of aluminum-based, particle-reinforced metal-matrix composite offer the following general advantages in comparison with connecting rods made of other materials:
  • MMC material Because of its particular structure, MMC material causes problems both during fabrication and in operation:
  • the aluminum alloy in the matrix is, as in all Al-based materials, very difficult to grind, which creates problems in achieving the narrow dimensional tolerances that apply to the openings at the large and small ends of the rod. Because of their hardness, the ceramic particles that comprise the reinforcement phase make the MMC material highly resistant to wear, but the opposing surface in the wear couple, e.g. the steel in a piston, may be subject to rapid wear. This can be prevented by providing the small end with a bronze bushing, although that does entail an increase in weight.
  • the coating can, if necessary, also cover the end plane of the large end to prevent the occurrence of galling damage from unintentional contact with adjacent components such as balance shafts.
  • coating metals include bearing metal, molybdenum, nickel, nickel-graphite and hard chrome.
  • the method used to apply the layer is chosen from among chemical and thermal coating methods, based on the functional requirements in each individual case, and on production engineering and financial considerations.
  • the thickness of the applied metal coating according to the invention is preferably between 0.1 and 2 mm.
  • MMC materials of the type in question can be surface- coated both chemically, e.g. with nickel, and via thermal spraying. In the latter case, the following known processes have been tested with good results:
  • the coating materials have consisted of, e.g. stainless steel, hard carbide steel, aluminum oxide and chromium oxide.
  • MMC metal-based, particle-reinforced metal-matrix composite
  • the properties of this type of material can be tailored specifically through the choices made in terms of matrix material, type and volume proportion of reinforcement phase, and fabrication method.
  • the component in question is a connecting rod
  • high stiffness combined with low weight and high fatigue strength are required, as is thermal linear expansion on a par with that of the steel in a connected crankshaft.
  • a number of MMC materials that can be used in the connecting rod in question are currently commercially available.
  • the metal matrix in this case consists of an aluminum alloy plus a reinforcement phase consisting of particles of aluminum oxide, silicon carbide or boron carbide. The properties are determined by the type of MMC chosen, and by the fabrication method used.
  • An example of a high-quality MMC material is produced by powder metallurgy, using a matrix from the AA2000 series reinforced with silicon carbide particles. The following properties are achieved:
  • the design which is optimized based on the material properties, pertains to a connecting rod for a racing motorcycle.
  • MMC connecting rods Two MMC connecting rods are test run in a racing motorcycle. The result is an engine that turns more readily and with clearly less vibration, on a par with engines equipped with balance shafts, and with less gyro effect, which is important to maneuverability in, e.g. moto-cross.
  • the bearing surfaces of these MMC connecting rods are provided with bushings to prevent any abrasion problems from affecting motor elements connected to the connecting rods as a result of the silicon carbide particles that the material contains. Even greater weight reduction can be achieved if the bushings are eliminated in accordance with the invention.
  • One aspect of the invention is based on a method of working a billet of MMC material by means of what is referred to here as HSM, or High-Speed Machining, and a component can be given its final form directly from the billet by means of this method.
  • the billet can be forge or cast, or may consist of a piece of extruded bar or a raw material produced in some other way.
  • High-speed machining is characterized in that the cutting tool achieves extremely high speeds in relation to the machined billet in comparison with conventional techniques.
  • the cutting tools that are relevant in this context are preferably milling tools and drills.
  • HSM high-speed machining
  • Finding the right cutting speed to produce the foregoing conditions that characterize HSM thus depends entirely on the material to be machined.
  • the cutting forces can be studied in connection with testing to determine the optimum cutting speed for HSM of a new material. These forces tend asymptotically toward zero as the criteria for HSM conditions are met. HSM conditions may thus be said to prevail when the cutting forces are diminishing. Under such conditions, it then remains to determine an optimum cutting speed for the material being machined. In conventional machining, the cutting forces increase with increasing cutting speeds.
  • HSM has been shown to yield unexpectedly good results when used on MMC materials.
  • the cutting tools are found to retain their sharpness for a long time, as though unaffected by the abrasive in the MMC material.
  • the reason for this has not been fully explained, since the internal process, i.e. what actually happens to the MMC material at the cutting point during machining, is not entirely understood.
  • One theory is that a cutting being cut from the material is brought to some extent into a liquid state in a small area immediately in front of the beak of the cutting tool, and that the abrasive particles imbedded in the material in the form of e.g. silicon carbide, boron carbide or aluminum oxide are carried away in the molten material and thus do not come into direct contact with the cut. This could explain why the cutting tools retaining their sharpness, in direct contrast to what occurs during conventional cutting operations.
  • a flange was produced from a raw billet of an MMC material, with a mill being used to remove all the material from the raw billet around the remaining flange.
  • the flange in this case was L-shaped, with a final thickness of 1 mm of material, and the sides of the flange measured 45 and 15 mm, respectively.
  • the values used during the machining in this example were: spindle speed 15,000 rpm, cutting speed 565 m/minute and feed speed 300 mm/minute. It took 2.5 minutes to create the flange.
  • the tool life of the cutting tool was measured in hours.
  • the proportion of SiC in the material was 40% in this example.
  • Tests were also conducted in which holes were drilled in MMC material containing 40% SiC. A number of holes were drilled using 6.9 mm HM bits, with a spindle speed of 15,000 rpm and a feed speed of 3000 mm/minute. The wear-out times for the drill bits were such that one bit could be used to drill 1000 holes.
  • the method according to the invention is applicable to all types of components that are to be made from MMC materials in cases where machine cutting is feasible in view of the final shape of the component.
  • the method is thus not limited to the depicted embodiments, but can be used in connection with any components where the choice of MMC as the material is advantageous.
  • the description above concerns a connecting rod whose surfaces that are to be corrected to ⁇ tolerance and/or surfaces that will be subject to wear are coated with an easy-to-work metallic layer.
  • a corresponding procedure may be applied to surfaces of corresponding type on components used in combustion engines, such as pistons, connecting rods, crankshafts, valve mechanism components and other fast-moving machine elements.

Landscapes

  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Physics & Mathematics (AREA)
  • Plasma & Fusion (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Materials Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Metallurgy (AREA)
  • Organic Chemistry (AREA)
  • Shafts, Cranks, Connecting Bars, And Related Bearings (AREA)
EP00946571A 2000-05-17 2000-05-17 Oberflächenbeschichte motorkomponente und herstellungsverfahren dafür Withdrawn EP1297195A1 (de)

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
PCT/SE2000/000982 WO2001088219A1 (en) 2000-05-17 2000-05-17 Surface coated motor component and process for producing it

Publications (1)

Publication Number Publication Date
EP1297195A1 true EP1297195A1 (de) 2003-04-02

Family

ID=20278935

Family Applications (1)

Application Number Title Priority Date Filing Date
EP00946571A Withdrawn EP1297195A1 (de) 2000-05-17 2000-05-17 Oberflächenbeschichte motorkomponente und herstellungsverfahren dafür

Country Status (2)

Country Link
EP (1) EP1297195A1 (de)
WO (1) WO2001088219A1 (de)

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US10399144B2 (en) 2015-03-02 2019-09-03 Halliburton Energy Services, Inc. Surface coating for metal matrix composites

Family Cites Families (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4941669A (en) * 1988-01-24 1990-07-17 Honda Giken Kogyo Kabushiki Kaisha Fiber-reinforced piston ring for internal combustion engine
WO1992005292A1 (en) * 1990-09-14 1992-04-02 Martin John Michael Murphy Metal matrix composite component
WO1996004485A1 (de) * 1994-08-01 1996-02-15 Gerold Pankl Pleuelstange
EP0863322B1 (de) * 1997-03-04 2003-11-05 Volkswagen Aktiengesellschaft Verfahren zum Herstellen eines Pleuels
EP1119647A2 (de) * 1997-12-19 2001-08-01 Lanxide Technology Company, Lp Teile mit aluminiumnitridoberfläche

Non-Patent Citations (1)

* Cited by examiner, † Cited by third party
Title
See references of WO0188219A1 *

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US10399144B2 (en) 2015-03-02 2019-09-03 Halliburton Energy Services, Inc. Surface coating for metal matrix composites

Also Published As

Publication number Publication date
WO2001088219A1 (en) 2001-11-22

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