WO2013060552A1 - Procédé de projection plasma - Google Patents

Procédé de projection plasma Download PDF

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Publication number
WO2013060552A1
WO2013060552A1 PCT/EP2012/069420 EP2012069420W WO2013060552A1 WO 2013060552 A1 WO2013060552 A1 WO 2013060552A1 EP 2012069420 W EP2012069420 W EP 2012069420W WO 2013060552 A1 WO2013060552 A1 WO 2013060552A1
Authority
WO
WIPO (PCT)
Prior art keywords
gas
plasma
flow rate
coating
bore
Prior art date
Application number
PCT/EP2012/069420
Other languages
German (de)
English (en)
Inventor
Leander Schramm
Clemens Maria Verpoort
David Cook
Original Assignee
Ford Global Technologies, Llc
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 Ford Global Technologies, Llc filed Critical Ford Global Technologies, Llc
Priority to IN2960CHN2014 priority Critical patent/IN2014CN02960A/en
Priority to EP12769643.3A priority patent/EP2771496A1/fr
Priority to RU2014121305A priority patent/RU2608247C2/ru
Priority to CN201280052953.1A priority patent/CN103890222A/zh
Priority to US14/236,049 priority patent/US20140154422A1/en
Publication of WO2013060552A1 publication Critical patent/WO2013060552A1/fr

Links

Classifications

    • 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
    • C23C4/14—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge characterised by the method of spraying for coating elongate material
    • C23C4/16—Wires; Tubes
    • 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
    • C23C4/131—Wire arc spraying
    • 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
    • C23C4/134—Plasma spraying
    • 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

Definitions

  • the present invention relates to a method for producing a coating by thermal spraying, in particular by plasma spraying, in which a component, in particular a bore of an internal combustion engine, e.g. is made of a light metal, is coated with an alloy, preferably with an iron alloy, wherein a plasma nozzle, which is supplied to a plasma gas and a transport gas is rotated about a wire and movable along a longitudinal axis of the bore, so that the bore from the inside and around coated in the axial direction of the bore.
  • a plasma nozzle which is supplied to a plasma gas and a transport gas is rotated about a wire and movable along a longitudinal axis of the bore, so that the bore from the inside and around coated in the axial direction of the bore.
  • EP 1 967 601 A2 From EP 1 967 601 A2 it is known that e.g. To coat an aluminum engine block, in particular its cylinder bore with an iron alloy while performing the arc wire spraying.
  • EP 1 967 601 A2 proposes to use an iron alloy which contains inter alia 5 to 25% by weight of chromium. It is essential in the EP 1 967 601 A2, that the molten iron also an additional powder, namely Borcabid is supplied.
  • the arc wire spraying method of EP 1 967 601 A2 is the so-called TWAS method, in which two wires are fed to a spray head in such a way that power is transmitted to the wires. When the two wires touch each other, a permanent short circuit causes an arc to melt the wires. Behind the nozzle is a nozzle from which compressed air or an inert gas such as nitrogen escapes. This gas stream atomizes the molten iron alloy and supplies it with the molten borocabid powder to the surface to be coated.
  • DE 44 1 1 296 A1 and DE 44 47 514 A1 deal with coatings by means of plasma spraying, although a metal powder or a filler wire are melted, and wherein the material mixture nitrogen by means of metallic nitrogen compounds is added to harden the coating.
  • EP 0 858 518 B1 deals with a method for producing a sliding surface on a light metal body by thermal spraying a coating of steel and molybdenum, wherein the wear layer is applied by means of plasma spraying.
  • EP 0 858 518 B1 describes that a mixture of steel powder with molybdenum powder is used.
  • EP 1 340 834 B1 a method for producing a cylinder tread layer is described. In this case, a rotating plasma spraying device is used, so that the engine block to be coated can rest during the coating.
  • the proportion of pores may be dependent on e.g. be influenced by the particle size of the coating powder targeted.
  • FR 2 924 365 A1 also deals with the plasma spraying of interior walls, whereby an additional spray powder is also used.
  • the capacity of the pores in the coating should be different, due to a change in the plasma spray parameters, e.g. the size, the hardness, the speed and the preheating temperature of the metal particles, or the metal powder should be possible.
  • Today's internal combustion engines or their engine blocks can be made of a metal or a light metal such. Cast aluminum or magnesium, in particular light metal blocks have on their cylinder bores an iron or metal layer.
  • the metal layer may be thermally sprayed. As thermal spraying methods, the above-mentioned methods are known.
  • the relevant prior art of the present invention includes the so-called PTWA inner transfer process (Plasma Transferred Wire Are).
  • PTWA inner transfer process Pulsma Transferred Wire Are
  • bores cylinder bores
  • the inner wall is thus completely coated all around and in the axial direction.
  • It is essential in the PTWA process that no metal powder is sprayed, but a homogeneous wire is melted and its melt droplets are transported to the inner wall to be coated and hit here, so that the coating is formed. So here only a single wire-shaped spray additive is supplied.
  • the plasma strikes the preheated, wire-shaped spray additive.
  • the plasma gas is usually an argon-hydrogen mixture.
  • PTWA As transport gas or atomizing gas, air or compressed air is used in the PTWA process.
  • the layers produced by this process are characterized by a low porosity.
  • the PTWA internal coating process has hitherto proven itself in the interior coating of cylinder bores, in particular of light metal blocks.
  • the coating usually has pores which reduce the friction between the piston rings and the cylinder surface because lubricant can accumulate in the pores.
  • EP 1 340 834 B1, EP 0 858 518 B1 and FR 2 924 365 A1 deal with an influence on the occurrence of pores in the coating.
  • the invention is based on the object to provide a method of the type mentioned above, with which a coating improved in this respect can be produced.
  • the gas flow it may be the plasma gas flow and / or the transport gas during the coating process at different positions along the longitudinal axis of the inner wall to be coated different amounts. If the flow rate of the gases varies over the axial length of the bore, different pore levels in the coating may occur depending on the flow rate amount. With the invention it has been advantageously recognized that a low gas flow rate produces a high pore content and a higher gas flow rate produces a small proportion of pores in the coating.
  • the inner coating can still be post-processed, for example honed, and / or lapped, to name just a few post-processing processes merely by way of example.
  • pistons are moved back and forth in a known manner.
  • the piston rings are in contact with the cylinder surface, ie with the coating.
  • the gas flow rate in the region of top dead center has a low amount, so that forms a high percentage of pores.
  • Even in the bottom dead center such a high percentage of pores in the coating can be provided.
  • the pore content may be reduced, so a higher flow rate can be set.
  • the plasma spraying device can be moved back and forth along the bore in the axial direction.
  • a circumferential inner coating can be produced together with the rotation. It can be started at an upper portion of the bore with the injection process.
  • the coating may have a small pore content, therefore the flow rate of the gas is limited to a high amount of e.g. 1 1001 / min can be set.
  • the plasma spraying device When the plasma spraying device is moved along the longitudinal axis towards the opposite end of the bore and reaches the top dead center region, it is convenient to reduce the flow rate and reduce it to a low amount of e.g. 4501 / min to produce a high porosity in the coating.
  • a lower flow rate causes a lower impact energy of the molten wire droplets on the inner wall.
  • a flow rate of a high amount e.g. 1 1001 / min, so that a coating with a low pore content is also achievable.
  • a high flow rate the remainder of the inner wall of the bore can now be coated.
  • the aim of the invention is therefore that over the axial length of the hole to be coated coating areas with different Pore shares are achievable, in particular, the top dead center has a particularly high percentage of pores. This is achieved in the invention via the variable flow rate of the gas, wherein in the top dead center, a low flow rate of eg 4501 / min is adjustable.
  • the transport gas is variably adjustable in its flow rate. It is also conceivable if the plasma gas can be variably adjusted together with the transport gas or per se in its flow rate.
  • the variable adjustment of the flow rate can be achieved via a control element which receives corresponding signals in order to set the desired or most advantageous flow rate for the respective position of the spray device along the bore to be coated.
  • the control may be in a preferred embodiment, a fast-switching solenoid valve, which preferably controls the flow infinitely.
  • the control is arranged in the respective supply line of the respective gas.
  • inventive method can also be used for coating other components.
  • Fig. 1 is a schematic view of a plasma spraying apparatus for carrying out the method.
  • Fig. 2 is a schematic section through a cylinder bore with an after
  • FIG. 1 shows a nozzle unit 1 of a PTWA internal coating device.
  • the PTWA (Plasma Transferred Wire Are) coating system is a system for coating bores, in particular cylinders in engine blocks of internal combustion engines.
  • the nozzle unit 1 consists of a cathode 2, a plasma nozzle 3, and the electrically conductive alloy wire 4 as Anode which is fed perpendicular to the plasma nozzle 3.
  • Tungsten is preferably used as the material for the cathode 2, which may be doped with thorium, for example.
  • the plasma gas 5, for example a mixture of argon and hydrogen, is supplied through bores located in the nozzle body 6 and located tangentially to the circumference.
  • the cathode holder 7 insulates the cathode 2 with respect to the nozzle body 6.
  • the alloy wire 4 is rotatably guided in the wire feed 15 and longitudinally displaceable.
  • the process is started by a high-voltage discharge which ionizes and dissociates the plasma gas 5 between alloy wire 4, nozzle body 6 and cathode 2.
  • the plasma thus generated flows through the plasma nozzle 3 at high speed.
  • the plasma gas 5 is transported toward the alloy wire 4 fed continuously perpendicular to the nozzle 3, whereby the electric circuit is closed.
  • the plasma jet 8 emerging from the plasma jet 3 is supplied with a transport gas 9 or an atomizing gas 9 via feed channels 10 and auxiliary nozzles 11.
  • the melting and the atomization of the alloy wire 4 are influenced by two phenomena.
  • the wire 4 is on the one hand by high currents, typically 65-90 amps, resistance heated.
  • the impact of the plasma jet 8 on the preheated wire 4 causes its melting at the wire end 12.
  • a plasma is generated within the plasma nozzle 3 by means of high-voltage discharge.
  • a targeted nitrogen gas flow so the transport gas 9 along the discharge path transports the plasma and the molten spray material 13 to the surface 14 of the cylinder bore to be coated.
  • FIG. 2 shows a schematic section through a cylinder bore 16 with a coating 14, wherein the coating 14 has been produced with a flow rate or gas flow rate which has been changed over the axial length X.
  • the coating is principally and merely by way of example divided into five regions, the dimensions of the regions shown, that is to say the axial extent thereof, being only an example.
  • the injection process according to the PTWA internal coating process has started in an upper ceiling area 17. The spraying device was moved from the upper ceiling area 17 towards the opposite end 18, the nozzle unit 1 rotating as described above.
  • an upper dead center area 19 which adjoins the upper ceiling area 17.
  • the upper dead center region 19 is adjoined by a middle region 20, to which a lower dead center region 21 adjoins.
  • a lower foot area 22 connects.
  • In the upper deck area 17 but also in the middle area 20, and also in the lower foot area 22 was injected at a high flow rate, which is why the coating in the respective area has a low pore content.
  • the region 21 is optional, so that the coating may also have only the regions 17, 19 and 20, the middle region 20 being guided to the end 18, and having been injected at a high flow rate, and therefore the coating then in the respective region 17 and 20 (until the end 18) may have a low pore content.

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  • 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)
  • Coating By Spraying Or Casting (AREA)

Abstract

L'invention concerne un procédé pour réaliser un revêtement par projection thermique, en particulier par projection plasma, dans lequel un composant, en particulier une chemise de cylindre, est pourvu d'un revêtement intérieur composé d'un alliage. Une buse à plasma (3), à laquelle sont fournis un gaz plasma (5) et un gaz de transport (9), est mise en rotation autour d'un fil (4) et peut être déplacée le long d'un axe longitudinal de l'alésage (16) de sorte que l'alésage (16) soit pourvu d'un revêtement vu dans le sens axial de l'alésage (16) et de l'intérieur sur toute sa surface. Il est prévu un flux de gaz variable ou un débit variable du gaz de transport (9) et/ou du gaz plasma (5), ce débit pouvant être réglé sur la longueur axiale (x) de l'alésage (16) à revêtir
PCT/EP2012/069420 2011-10-27 2012-10-02 Procédé de projection plasma WO2013060552A1 (fr)

Priority Applications (5)

Application Number Priority Date Filing Date Title
IN2960CHN2014 IN2014CN02960A (fr) 2011-10-27 2012-10-02
EP12769643.3A EP2771496A1 (fr) 2011-10-27 2012-10-02 Procédé de projection plasma
RU2014121305A RU2608247C2 (ru) 2011-10-27 2012-10-02 Способ плазменного напыления
CN201280052953.1A CN103890222A (zh) 2011-10-27 2012-10-02 等离子体喷射方法
US14/236,049 US20140154422A1 (en) 2011-10-27 2012-10-02 Plasma spraying process

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
DE102011085324.3 2011-10-27
DE102011085324A DE102011085324A1 (de) 2011-10-27 2011-10-27 Plasmaspritzverfahren

Publications (1)

Publication Number Publication Date
WO2013060552A1 true WO2013060552A1 (fr) 2013-05-02

Family

ID=47002858

Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/EP2012/069420 WO2013060552A1 (fr) 2011-10-27 2012-10-02 Procédé de projection plasma

Country Status (7)

Country Link
US (1) US20140154422A1 (fr)
EP (1) EP2771496A1 (fr)
CN (1) CN103890222A (fr)
DE (1) DE102011085324A1 (fr)
IN (1) IN2014CN02960A (fr)
RU (1) RU2608247C2 (fr)
WO (1) WO2013060552A1 (fr)

Cited By (1)

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WO2015074775A1 (fr) * 2013-11-20 2015-05-28 Ks Aluminium-Technologie Gmbh Procédé de réalisation par projection d'une surface de cylindre d'un bloc-moteur de moteur à combustion interne et un tel bloc moteur

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PT3116636T (pt) 2014-03-11 2020-10-19 Tekna Plasma Systems Inc Processo e aparelho para produzir partículas de pó por atomização de um material de alimentação com a forma de um elemento alongado
US20150376761A1 (en) * 2014-06-30 2015-12-31 United Technologies Corporation Systems and methods for plasma spray coating
CN105986919B (zh) * 2015-01-28 2019-08-27 代卫东 一种改进的发动机缸体及其制造工艺
DE102016116815A1 (de) * 2016-09-08 2018-03-08 Dr. Ing. H.C. F. Porsche Aktiengesellschaft Verfahren zur Beschichtung eines Zylinders einer Verbrennungskraftmaschine und Zylinder für eine Verbrennungskraftmaschine
DE102021106846A1 (de) 2021-03-19 2022-09-22 Rolls-Royce Solutions GmbH Zylinderlaufbahn mit Teilbereichen und Verfahren zur Herstellung der Zylinderlaufbahn, sowie Zylinder und Brennkraftmaschine
DE102022105774A1 (de) 2022-03-11 2023-09-14 Bayerische Motoren Werke Aktiengesellschaft Verfahren zum Bearbeiten eines Kurbelgehäuses sowie Kurbelgehäuse

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DE4411296A1 (de) 1994-01-14 1995-07-20 Castolin Sa Zwei- oder mehrphasige Beschichtung
DE4447514A1 (de) 1994-01-14 1996-02-01 Castolin Sa Verfahren zum Herstellen eines Hilfsmittels für das Beschichten durch thermisches Spritzen, Plasmapulver-Auftragsschweißen oder Lichtbogenschweißen
EP0858518B1 (fr) 1995-10-31 2000-02-09 Volkswagen Aktiengesellschaft Procede de production d'une surface de frottement sur un alliage des metaux legers
US20040031776A1 (en) * 2002-04-29 2004-02-19 Gevelber Michael Alan Feedback enhanced plasma spray tool
EP1967601A2 (fr) 2007-03-06 2008-09-10 Bayerische Motoren Werke Aktiengesellschaft Procédé de fabrication d'un revêtement
EP1340834B1 (fr) 2002-02-27 2009-04-22 Sulzer Metco AG Revêtements de surfaces de contact de cylindres pour moteurs à combustion et procédé de sa fabrication
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FR2924365A1 (fr) 2007-12-03 2009-06-05 Peugeot Citroen Automobiles Sa Procede de fabrication d'un revetement comportant des pores aptes a retenir un lubrifiant et piece comportant un tel revetement
US20100104736A1 (en) * 2008-10-23 2010-04-29 Baker Hughes Incorporated Method and apparatus for automated application of hardfacing material to drill bits

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US5047612A (en) * 1990-02-05 1991-09-10 General Electric Company Apparatus and method for controlling powder deposition in a plasma spray process
DE4411296A1 (de) 1994-01-14 1995-07-20 Castolin Sa Zwei- oder mehrphasige Beschichtung
DE4447514A1 (de) 1994-01-14 1996-02-01 Castolin Sa Verfahren zum Herstellen eines Hilfsmittels für das Beschichten durch thermisches Spritzen, Plasmapulver-Auftragsschweißen oder Lichtbogenschweißen
EP0858518B1 (fr) 1995-10-31 2000-02-09 Volkswagen Aktiengesellschaft Procede de production d'une surface de frottement sur un alliage des metaux legers
EP1340834B1 (fr) 2002-02-27 2009-04-22 Sulzer Metco AG Revêtements de surfaces de contact de cylindres pour moteurs à combustion et procédé de sa fabrication
US20040031776A1 (en) * 2002-04-29 2004-02-19 Gevelber Michael Alan Feedback enhanced plasma spray tool
EP1967601A2 (fr) 2007-03-06 2008-09-10 Bayerische Motoren Werke Aktiengesellschaft Procédé de fabrication d'un revêtement
US20090104348A1 (en) * 2007-10-23 2009-04-23 Nissan Motor Co., Ltd. Sprayed film forming method and apparatus
FR2924365A1 (fr) 2007-12-03 2009-06-05 Peugeot Citroen Automobiles Sa Procede de fabrication d'un revetement comportant des pores aptes a retenir un lubrifiant et piece comportant un tel revetement
US20100104736A1 (en) * 2008-10-23 2010-04-29 Baker Hughes Incorporated Method and apparatus for automated application of hardfacing material to drill bits

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Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2015074775A1 (fr) * 2013-11-20 2015-05-28 Ks Aluminium-Technologie Gmbh Procédé de réalisation par projection d'une surface de cylindre d'un bloc-moteur de moteur à combustion interne et un tel bloc moteur
CN105745350A (zh) * 2013-11-20 2016-07-06 Ks华域铝技术有限责任公司 制造内燃机的气缸体曲轴箱的喷涂的气缸工作表面的方法和这种气缸体曲轴箱
RU2647064C2 (ru) * 2013-11-20 2018-03-13 Кс Хуаюй Алутек Гмбх Способ изготовления напыленной рабочей поверхности цилиндра в блоке цилиндров двигателя внутреннего сгорания, а также такой блок цилиндров

Also Published As

Publication number Publication date
RU2014121305A (ru) 2015-12-10
CN103890222A (zh) 2014-06-25
DE102011085324A1 (de) 2013-05-02
US20140154422A1 (en) 2014-06-05
IN2014CN02960A (fr) 2015-07-03
RU2608247C2 (ru) 2017-01-17
EP2771496A1 (fr) 2014-09-03

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