WO2015101699A1 - Plasma-transfer-arc-welding (pta) coating for use on valve seats, method for manufacturing, pta coating, and use of the pta coating on valve seat surfaces - Google Patents

Plasma-transfer-arc-welding (pta) coating for use on valve seats, method for manufacturing, pta coating, and use of the pta coating on valve seat surfaces Download PDF

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Publication number
WO2015101699A1
WO2015101699A1 PCT/FI2014/050005 FI2014050005W WO2015101699A1 WO 2015101699 A1 WO2015101699 A1 WO 2015101699A1 FI 2014050005 W FI2014050005 W FI 2014050005W WO 2015101699 A1 WO2015101699 A1 WO 2015101699A1
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WO
WIPO (PCT)
Prior art keywords
coating
pta
valve
valve seat
plasma
Prior art date
Application number
PCT/FI2014/050005
Other languages
French (fr)
Inventor
Aulis Silvonen
Edoardo HLEDE
Jyrki SUUTALA
Mattia PUJATTI
Original Assignee
Wärtsilä Finland Oy
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 Wärtsilä Finland Oy filed Critical Wärtsilä Finland Oy
Priority to PCT/FI2014/050005 priority Critical patent/WO2015101699A1/en
Publication of WO2015101699A1 publication Critical patent/WO2015101699A1/en

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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
    • C23C24/00—Coating starting from inorganic powder
    • C23C24/08—Coating starting from inorganic powder by application of heat or pressure and heat
    • C23C24/10—Coating starting from inorganic powder by application of heat or pressure and heat with intermediate formation of a liquid phase in the layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K10/00—Welding or cutting by means of a plasma
    • B23K10/02—Plasma welding
    • B23K10/027—Welding for purposes other than joining, e.g. build-up welding
    • 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
    • C23C4/04—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge characterised by the coating material
    • C23C4/06—Metallic material
    • 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
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K2101/00—Articles made by soldering, welding or cutting
    • B23K2101/003—Pistons

Definitions

  • PLASMA-TRANSFER-ARC-WELDING COATING FOR USE ON VALVE SEATS, METHOD FOR MANUFACTURING, PTA COATING, AND USE OF THE PTA
  • the invention relates to use of PTA coatings on valve seat surfaces, and method for manufacturing a PTA coating on valve seat surfaces.
  • the invention also relates to combustion engine exhaust valves comprising a PTA coatings on seat surfaces.
  • valves relating to embodiments of the invention are used in internal combustion engines, for example in internal combustion engines of marine vessels.
  • Engines relating to the invention are used, for example, as main propulsion engines or auxiliary engines in marine vessels or in power plants for the pro- 15 duction of heat and/or electricity.
  • valves in an internal combustion engine are well known in the art.
  • Engine valve seats and contacting surface of the valve head experience severe circumstances of corrosion and wear.
  • the valve comprises a body, a head, and a contact surface on a valve head which is adapted to periodically
  • valve head 20 enter into gas-sealing engagement with a valve seat or seat ring.
  • This repetitive engagement or contact of valve head with valve seat requires gas-tight contact, because valve leakage through valve causes problems with combustion and operation of the engine: incomplete combustion, power loss, engine efficiency, compression ratio, exhaust emissions and engine and/or compo-
  • valve seats and valve contacting surfaces are under corrosive environment and subjected to continuous wear, these surfaces usually comprise a coating of hard material to counter these demands.
  • One commonly known material for these surfaces is Stellite.
  • the coating on the valve surfaces 30 must be high-quality to provide gas-sealing engagement, and one known and commonly used process to make coatings is Plasma transferred arc (PTA).
  • Plasma transferred arc (PTA) welding is the mostly used method for depositing high-quality metallurgically fused deposits on relatively low cost surfaces. Medium and high hardness materials can be deposited on a variety of substrates to achieve diverse properties such as mechanical strength, wear, corrosion and creep resistance.
  • Prior art comprises publication US20121 18402, which discloses a gas cylinder valve has a permanent coating of a solid lubricant on at least one of its internal frictional surfaces.
  • the solid lubricant consists of or comprises tungsten disulfide.
  • Prior art comprises publication US2007163655, which discloses a gate valve with the at least one of the engaging faces of the gate and the seat ring can have friction-resistant coating of molybdenum disulfide on a hardened outer layer.
  • Prior art publication US2004043160 discloses a method for coating an article, such as gas turbine assembly, with Plasma Transferred Arc (PTA) welding.
  • PTA Plasma Transferred Arc
  • the high temperature contact between seat surfaces can suffer higher wear rates (dry friction wear) due to low lubricity resulting in reduced components lifetime and engine failure.
  • valve seat surfaces consists in the use of Cobalt- based alloys, whose deposition is carried out via Plasma Transferred Arc (PTA) welding technique.
  • PTA Plasma Transferred Arc
  • An object of the invention is to alleviate and eliminate the problems or drawbacks relating to the known prior art. Another object of the invention is to provide a high quality coating for valves and valve seat surfaces, which possesses good wear-resistant and increased lifetime. Another object of the invention is to provide economically internal combustion engines and marine vessels with increased lifetime by providing a coating for valves and valve seat surfaces with enhanced lubricating properties.
  • the object of the invention can be achieved by the features of independent claims.
  • the invention relates to a PTA coating for use on valve seat or valve surfaces according to claim 1 , to an internal combustion engine valve accord- ing to claim 4, to an internal combustion engine according to claim 5, to a marine vessel according to claim 6, to a method for manufacturing a PTA coating according to claim 7 and to use of PTA coating according to claim 9.
  • a PTA coating for use on valve seat or valve contacting surfaces of an internal combustion engine is prepared by Plasma-Transfer-Arc-welding (PTA) and is composite material, which comprises a metal matrix and solid lubricating particles within the metal matrix.
  • PTA Plasma-Transfer-Arc-welding
  • the valve is arranged to periodically enter into gas-sealing engagement with a valve seat, so as to enable the operation of the cylinder and/or internal combustion engine.
  • the coating deposition is carried out via Plasma Transferred Arc welding (PTA). This technique provides the necessary coating thickness and adhesion to the substrate, which together with the above-mentioned constituents allow to realise mechanically resistant system and reduce the wear.
  • the metal matrix advantageously is based on heat resistant ferrous or non- ferrous alloys.
  • Heat resistant alloys relate with this invention to such metal alloys that can be used in internal combustion engines on gas exchange valves or on other parts of internal combustion engine.
  • the metal ma- trix is based on one of the following: nickel and its alloys and cobalt and its alloys. It is also possible that matrix is based on other hard metals.
  • the solid lubricating particles are comprised of sulphides, sulphates or fluorides.
  • Advantageously self-lubricating particles are made of at least one of the following: CaF2, BaF2, MoS2, WS2, FeS, MnS, h-BN (hexagonal boron nitride), CeF3.
  • the solid lubricating particles are made of at least one of such materials as selenides and tellurides (chalcogenides) of molybdenum, tungsten, niobium, tantalum, titanium (eg. MoSe2, TaSe2, TiTe2), monochalcenides (GaS, GaSe, SnSe), chlorides of cadmium, cobalt, lead, cerium, zirconium (eg. CdCI2, CoCI2, PbCI2, CeF3, Pbl2) and also some borates (eg. Na2B4O7) or sulfates (Ag2SO4, CaSo4, BaSo4, SrSo4).
  • selenides and tellurides chalcogenides
  • molybdenum tungsten, niobium, tantalum, titanium (eg. MoSe2, TaSe2, TiTe2), monochalcenides (GaS, GaSe, SnSe), chlorides of cadmium, cobalt, lead,
  • the coating further comprises particles at least one of the following: metal boride, metal carbide, metal nitride, or metal carbonitride, to increase hardness and wear-resistance and to contribute to the lubricating action.
  • metal boride metal carbide, metal nitride, or metal carbonitride
  • preferred metal in the compound include tungsten, vanadium, titanium, tantalum, niobium, chromium, molybdenum, or mixtures of these metals.
  • the hardening par- tides can be made at least one of the following: Tungsten carbide (WC), titanium carbide (TiC), chromium carbide (Cr3C2).
  • a valve of an internal combustion engine comprises the said PTA coating on a contact surface of the valve head.
  • the valve comprises a body, a head, and a contact surface on a head to be adapted to periodically enter into gas-sealing engagement with a valve seat, so as to enable the operation of the cylinder and/or internal combustion engine.
  • the valve seat surface comprises the said PTA coating of the present invention.
  • One further embodiment of the invention include an internal combustion engine, which comprises said PTA coating.
  • One further embodiment of the invention includes a marine vessel, which comprises the said PTA coating on valve head or on valve seat surface of an internal combustion engine.
  • the coating material comprising solid lubricating particles and a matrix metal based on heat resistant ferrous or non-ferrous alloys.
  • the metal matrix is based on one of the following: cobalt or nickel or their alloys.
  • the coating material is in powder form suitable for deposition by plasma transferred arc welding.
  • the matrix alloy powder and solid lubricant particles are mixed to form coating material powder before being inserted into a plasma torch.
  • the matrix alloy powder and solid lubricant particles are provided as a mixed slurry and deposited on a substrate and then scanned with the plasma torch.
  • One further embodiment of the invention is to use the said PTA coating prepared by the above method in a piston engine.
  • One further embodiment of the invention is to use the said PTA coating prepared by the above method in a piston engine of a marine vessel.
  • the present invention provides an improvement to drawbacks of the prior art.
  • the present invention also provides many advantages over the known prior art, such as:
  • Figures 1 a and 1 b illustrate a principle of an exemplary arrangement of PTA coating on valve and valve seat according to an advantageous embodiment of the invention
  • Figure 2 illustrates an exemplary structure of the method for manufacturing a PTA coating according to an advantageous embodiment of the invention.
  • Figure 1 a and 1 b illustrate a one exemplary internal combustion engine (1 ) structure, where is cylinder head (2) comprising valves (4) arranged to periodically enter into gas-sealing engagement with a valve seat.
  • Cylinder sleeve (6) defines main combustion area (7) with piston and valves (4).
  • Fig 1 b illustrates more detailed arrangement and the relation of valve (4) and valve seat (5).
  • the valve (4) head and valve seat (5) comprise a PTA coating (8) with solid lubricants.
  • the PTA coating can be arranged on valve head or valve seat or both surfaces.
  • the example of Fig 1 b shows the PTA coating (8) on both surfaces.
  • Fig 2 illustrates a basic principle of PTA process, where on a substrate (9) is deposited coating material (10) by plasma arc.
  • the PTA coating for use on valve seat or valve contacting surfaces of an inter- nal combustion engine is prepared by Plasma-Transfer-Arc-welding (PTA).
  • the coating material is composite material, which comprises a metal matrix and solid lubricating particles within the metal matrix.
  • the valve is arranged to periodically enter into gas-sealing engagement with a valve seat, so as to enable the operation of the cylinder and/or internal combustion engine.
  • the metal matrix advantageously is based on heat resistant ferrous or non- ferrous alloys.
  • the metal matrix is based on one of the following: nickel and its alloys or cobalt and its alloys. It is also possible that matrix is based on other hard metals.
  • the solid lubricating particles are comprised of compounds of sulphides, sulphates or fluorides.
  • Advantageously self-lubricating particles are made of at least one of the following: CaF2, BaF2, MoS2, WS2, FeS, MnS, h-BN (hexagonal boron nitride), CeF3.
  • the solid lubricating par- tides are made of at least one of such materials as sulphides, selenides and tellurides (chalcogenides) of molybdenum, tungsten, niobium, tantalum, titanium (eg. WS2, MoSe2, TaSe2, TiTe2), monochalcenides (GaS, GaSe, SnSe), chlorides of cadmium, cobalt, lead, cerium, zirconium (eg. CdCI2, CoCI2, PbCI2, CeF3, Pbl2) and also some borates (eg. Na2B4O7) or sulfates (Ag2SO4, CaSo4, BaSo4, SrSo4).
  • sulphides selenides and tellurides
  • chalcogenides of molybdenum, tungsten, niobium, tantalum, titanium (eg. WS2, MoSe2, TaSe2, TiTe2), monochalcenides (GaS, GaSe
  • the coating further comprises particles of at least one of the following: metal boride, metal carbide, metal nitride, or metal carbonitride, to increase hardness and wear-resistance and to contribute to the lubricating action.
  • metal boride metal carbide
  • metal nitride metal carbonitride
  • preferred metal in the compound include tungsten, vanadium, titanium, tantalum, niobium, chromium, molybdenum, or mixtures of these metals.
  • the hardening particles are selected from the following: Tungsten carbide (WC), titanium carbide (TiC), chromium carbide (Cr3C2).
  • valve of an internal combustion engine comprises the said PTA coating on a contact surface of the valve head.
  • the valve comprises a body, a head, and a contact surface on a head to be adapted to periodically enter into gas-sealing engagement with a valve seat, so as to enable the operation of the cylinder and/or internal combustion engine.
  • valve seat surface comprises the said PTA coating of the present invention.
  • a further example of an embodiment of the invention include an internal combustion engine, which comprises said PTA coating
  • a further example of an embodiment of the invention includes a marine vessel, which comprises the said PTA coating on valve head or on valve seat surface of an internal combustion engine.
  • PTA coating is manufactured by a method comprising steps of:
  • the substrate with a coating material by Plasma-Transferred-Arc welding, the coating material comprising solid lubricating particles and a matrix metal based on of one of the following: cobalt or nickel or their alloys.
  • the coating material being in powder form suitable for deposition by plasma transferred arc welding.
  • a further example of an additional embodiment of the invention is that the matrix alloy powder and solid lubricant particles are mixed to form coating material powder before being inserted into a plasma torch.
  • a further example of an additional embodiment of the invention is that the matrix alloy powder and solid lubricant particles are provided as a mixed slurry and deposited on a substrate and then scanned with the plasma torch.
  • One further embodiment of the invention is to use the said PTA coating prepared by the above method in an internal combustion engine of a marine ves- sel.

Abstract

A PTA coating for use on valve seat or valve head contacting surfaces of an internal combustion engine wherein coating is welded by Plasma-Transfer-Arc- welding (PTA), and the coating material is a composite material comprising solid lubricating particles within a metal matrix, the metal matrix being based on heat resistant ferrous or non-ferrous alloys.

Description

PLASMA-TRANSFER-ARC-WELDING (PTA) COATING FOR USE ON VALVE SEATS, METHOD FOR MANUFACTURING, PTA COATING, AND USE OF THE PTA
COATING ON VALVE SEAT SURFACES
TECHNICAL FIELD OF THE INVENTION
5 The invention relates to use of PTA coatings on valve seat surfaces, and method for manufacturing a PTA coating on valve seat surfaces. The invention also relates to combustion engine exhaust valves comprising a PTA coatings on seat surfaces.
10 BACKGROUND OF THE INVENTION
The valves relating to embodiments of the invention are used in internal combustion engines, for example in internal combustion engines of marine vessels. Engines relating to the invention are used, for example, as main propulsion engines or auxiliary engines in marine vessels or in power plants for the pro- 15 duction of heat and/or electricity.
The operation of valves in an internal combustion engine is well known in the art. Engine valve seats and contacting surface of the valve head experience severe circumstances of corrosion and wear. The valve comprises a body, a head, and a contact surface on a valve head which is adapted to periodically
20 enter into gas-sealing engagement with a valve seat or seat ring. This repetitive engagement or contact of valve head with valve seat requires gas-tight contact, because valve leakage through valve causes problems with combustion and operation of the engine: incomplete combustion, power loss, engine efficiency, compression ratio, exhaust emissions and engine and/or compo-
25 nent life.
Because the valve seats and valve contacting surfaces are under corrosive environment and subjected to continuous wear, these surfaces usually comprise a coating of hard material to counter these demands. One commonly known material for these surfaces is Stellite. The coating on the valve surfaces 30 must be high-quality to provide gas-sealing engagement, and one known and commonly used process to make coatings is Plasma transferred arc (PTA). Plasma transferred arc (PTA) welding is the mostly used method for depositing high-quality metallurgically fused deposits on relatively low cost surfaces. Medium and high hardness materials can be deposited on a variety of substrates to achieve diverse properties such as mechanical strength, wear, corrosion and creep resistance.
Prior art comprises publication US20121 18402, which discloses a gas cylinder valve has a permanent coating of a solid lubricant on at least one of its internal frictional surfaces. The solid lubricant consists of or comprises tungsten disulfide. Prior art comprises publication US2007163655, which discloses a gate valve with the at least one of the engaging faces of the gate and the seat ring can have friction-resistant coating of molybdenum disulfide on a hardened outer layer.
Prior art publication US2004043160 discloses a method for coating an article, such as gas turbine assembly, with Plasma Transferred Arc (PTA) welding.
There are however some disadvantages relating to the known prior art, such as, none of the prior art disclose a PTA coating or use of PTA coatings with solid lubricants on valve seat or valve head surfaces of an internal combustion engine. None of the prior art disclose a method for preparing a PTA coating with solid lubricants on valve seat or valve head surfaces of an internal combustion engine.
However, internal combustion engines are facing more opportunities to run with new cleaner fuels. As a result of this, exhaust valves and seat surfaces or seat rings have increasing demands related to wear resistance and corrosion which both affect to their operation.
With mentioned fuels, the high temperature contact between seat surfaces can suffer higher wear rates (dry friction wear) due to low lubricity resulting in reduced components lifetime and engine failure.
Current standard solution for valve seat surfaces consists in the use of Cobalt- based alloys, whose deposition is carried out via Plasma Transferred Arc (PTA) welding technique. New material solutions enabling lower friction be- tween the two contact surfaces can reduce this type of wear bringing consequently increased exhaust valve and valve seat lifetime.
SUMMARY OF THE INVENTION An object of the invention is to alleviate and eliminate the problems or drawbacks relating to the known prior art. Another object of the invention is to provide a high quality coating for valves and valve seat surfaces, which possesses good wear-resistant and increased lifetime. Another object of the invention is to provide economically internal combustion engines and marine vessels with increased lifetime by providing a coating for valves and valve seat surfaces with enhanced lubricating properties.
The object of the invention can be achieved by the features of independent claims. The invention relates to a PTA coating for use on valve seat or valve surfaces according to claim 1 , to an internal combustion engine valve accord- ing to claim 4, to an internal combustion engine according to claim 5, to a marine vessel according to claim 6, to a method for manufacturing a PTA coating according to claim 7 and to use of PTA coating according to claim 9.
According to an embodiment of the invention, a PTA coating for use on valve seat or valve contacting surfaces of an internal combustion engine, is prepared by Plasma-Transfer-Arc-welding (PTA) and is composite material, which comprises a metal matrix and solid lubricating particles within the metal matrix. The valve is arranged to periodically enter into gas-sealing engagement with a valve seat, so as to enable the operation of the cylinder and/or internal combustion engine. The coating deposition is carried out via Plasma Transferred Arc welding (PTA). This technique provides the necessary coating thickness and adhesion to the substrate, which together with the above-mentioned constituents allow to realise mechanically resistant system and reduce the wear.
The metal matrix advantageously is based on heat resistant ferrous or non- ferrous alloys. Heat resistant alloys relate with this invention to such metal alloys that can be used in internal combustion engines on gas exchange valves or on other parts of internal combustion engine. Advantageously the metal ma- trix is based on one of the following: nickel and its alloys and cobalt and its alloys. It is also possible that matrix is based on other hard metals.
According to an additional embodiment of the invention, the solid lubricating particles are comprised of sulphides, sulphates or fluorides. Advantageously self-lubricating particles are made of at least one of the following: CaF2, BaF2, MoS2, WS2, FeS, MnS, h-BN (hexagonal boron nitride), CeF3.
According to another embodiment of the invention, the solid lubricating particles are made of at least one of such materials as selenides and tellurides (chalcogenides) of molybdenum, tungsten, niobium, tantalum, titanium (eg. MoSe2, TaSe2, TiTe2), monochalcenides (GaS, GaSe, SnSe), chlorides of cadmium, cobalt, lead, cerium, zirconium (eg. CdCI2, CoCI2, PbCI2, CeF3, Pbl2) and also some borates (eg. Na2B4O7) or sulfates (Ag2SO4, CaSo4, BaSo4, SrSo4).
According to an additional embodiment of the invention the coating further comprises particles at least one of the following: metal boride, metal carbide, metal nitride, or metal carbonitride, to increase hardness and wear-resistance and to contribute to the lubricating action. Examples of preferred metal in the compound include tungsten, vanadium, titanium, tantalum, niobium, chromium, molybdenum, or mixtures of these metals. Advantageously the hardening par- tides can be made at least one of the following: Tungsten carbide (WC), titanium carbide (TiC), chromium carbide (Cr3C2).
According to another embodiment of the invention, a valve of an internal combustion engine comprises the said PTA coating on a contact surface of the valve head. The valve comprises a body, a head, and a contact surface on a head to be adapted to periodically enter into gas-sealing engagement with a valve seat, so as to enable the operation of the cylinder and/or internal combustion engine.
According to another embodiment of the invention, the valve seat surface comprises the said PTA coating of the present invention. One further embodiment of the invention include an internal combustion engine, which comprises said PTA coating One further embodiment of the invention includes a marine vessel, which comprises the said PTA coating on valve head or on valve seat surface of an internal combustion engine.
According to one embodiment of the invention the PTA coating is manufac- tured by a method comprising steps of:
- providing a valve seat surface or a valve head surface as a substrate
- coating the substrate with a coating material by Plasma-Transferred-Arc welding, the coating material comprising solid lubricating particles and a matrix metal based on heat resistant ferrous or non-ferrous alloys. Advantageously the metal matrix is based on one of the following: cobalt or nickel or their alloys.
Naturally the coating material is in powder form suitable for deposition by plasma transferred arc welding.
According to an additional embodiment of the invention the matrix alloy powder and solid lubricant particles are mixed to form coating material powder before being inserted into a plasma torch.
According to an additional embodiment of the invention the matrix alloy powder and solid lubricant particles are provided as a mixed slurry and deposited on a substrate and then scanned with the plasma torch. One further embodiment of the invention is to use the said PTA coating prepared by the above method in a piston engine.
One further embodiment of the invention is to use the said PTA coating prepared by the above method in a piston engine of a marine vessel.
The present invention provides an improvement to drawbacks of the prior art. The present invention also provides many advantages over the known prior art, such as:
- it enables the use of new and cleaner fuels without compromising component reliability or fuel flexibility
- Lifetime increase for exhaust valves and valve seat surface or seat rings - Reduction of operational cost
- solid lubricants provide ability to work under high loads and higher thermal stability. BRIEF DESCRIPTION OF THE DRAWINGS
Next the invention will be described in greater detail with reference to exemplary embodiments in accordance with the accompanying drawings, in which: Figures 1 a and 1 b illustrate a principle of an exemplary arrangement of PTA coating on valve and valve seat according to an advantageous embodiment of the invention,
Figure 2 illustrates an exemplary structure of the method for manufacturing a PTA coating according to an advantageous embodiment of the invention.
DETAILED DESCRIPTION
Figure 1 a and 1 b illustrate a one exemplary internal combustion engine (1 ) structure, where is cylinder head (2) comprising valves (4) arranged to periodically enter into gas-sealing engagement with a valve seat. Cylinder sleeve (6) defines main combustion area (7) with piston and valves (4). Fig 1 b illustrates more detailed arrangement and the relation of valve (4) and valve seat (5). The valve (4) head and valve seat (5) comprise a PTA coating (8) with solid lubricants.
According to embodiments of the invention the PTA coating can be arranged on valve head or valve seat or both surfaces. The example of Fig 1 b shows the PTA coating (8) on both surfaces.
Fig 2 illustrates a basic principle of PTA process, where on a substrate (9) is deposited coating material (10) by plasma arc.
The PTA coating for use on valve seat or valve contacting surfaces of an inter- nal combustion engine, is prepared by Plasma-Transfer-Arc-welding (PTA). The coating material is composite material, which comprises a metal matrix and solid lubricating particles within the metal matrix. The valve is arranged to periodically enter into gas-sealing engagement with a valve seat, so as to enable the operation of the cylinder and/or internal combustion engine. The metal matrix advantageously is based on heat resistant ferrous or non- ferrous alloys. Advantageously the metal matrix is based on one of the following: nickel and its alloys or cobalt and its alloys. It is also possible that matrix is based on other hard metals. An example of an embodiment of the invention is that the solid lubricating particles are comprised of compounds of sulphides, sulphates or fluorides. Advantageously self-lubricating particles are made of at least one of the following: CaF2, BaF2, MoS2, WS2, FeS, MnS, h-BN (hexagonal boron nitride), CeF3.
An example of an embodiment of the invention is that the solid lubricating par- tides are made of at least one of such materials as sulphides, selenides and tellurides (chalcogenides) of molybdenum, tungsten, niobium, tantalum, titanium (eg. WS2, MoSe2, TaSe2, TiTe2), monochalcenides (GaS, GaSe, SnSe), chlorides of cadmium, cobalt, lead, cerium, zirconium (eg. CdCI2, CoCI2, PbCI2, CeF3, Pbl2) and also some borates (eg. Na2B4O7) or sulfates (Ag2SO4, CaSo4, BaSo4, SrSo4).
An example of an embodiment of the invention is that the coating further comprises particles of at least one of the following: metal boride, metal carbide, metal nitride, or metal carbonitride, to increase hardness and wear-resistance and to contribute to the lubricating action. Examples of preferred metal in the compound include tungsten, vanadium, titanium, tantalum, niobium, chromium, molybdenum, or mixtures of these metals. Advantageously the hardening particles are selected from the following: Tungsten carbide (WC), titanium carbide (TiC), chromium carbide (Cr3C2).
An example of an embodiment of the invention is that the valve of an internal combustion engine comprises the said PTA coating on a contact surface of the valve head. The valve comprises a body, a head, and a contact surface on a head to be adapted to periodically enter into gas-sealing engagement with a valve seat, so as to enable the operation of the cylinder and/or internal combustion engine. A further example of an embodiment of the invention is that the valve seat surface comprises the said PTA coating of the present invention.
A further example of an embodiment of the invention include an internal combustion engine, which comprises said PTA coating A further example of an embodiment of the invention includes a marine vessel, which comprises the said PTA coating on valve head or on valve seat surface of an internal combustion engine.
A further example of one embodiment of the invention, which is that the PTA coating is manufactured by a method comprising steps of:
- providing a valve seat surface or a valve head surface as a substrate
- coating the substrate with a coating material by Plasma-Transferred-Arc welding, the coating material comprising solid lubricating particles and a matrix metal based on of one of the following: cobalt or nickel or their alloys. The coating material being in powder form suitable for deposition by plasma transferred arc welding.
A further example of an additional embodiment of the invention is that the matrix alloy powder and solid lubricant particles are mixed to form coating material powder before being inserted into a plasma torch. A further example of an additional embodiment of the invention is that the matrix alloy powder and solid lubricant particles are provided as a mixed slurry and deposited on a substrate and then scanned with the plasma torch.
One further embodiment of the invention is to use the said PTA coating prepared by the above method in an internal combustion engine of a marine ves- sel.
The invention has been explained above with reference to the aforementioned embodiments, and several advantages of the invention have been demonstrated. It is clear that the invention is not only restricted to these embodiments, but comprises all possible embodiments within the spirit and scope of the inventive thought and the following patent claims.
Reference numbers:
1 Combustion engine
2 Cylinder head 6 Cylinder sleeve Main combustion area PTA coating substrate
coating material

Claims

1 . A Plasma-Transfer-Arc-welding (PTA) coating for use on valve seat or valve head contacting surfaces of an internal combustion engine characterized in that the coating is welded by Plasma-Transfer-Arc-welding (PTA), and the coating material being a composite material comprising solid lubricating particles within a metal matrix, the metal matrix being based on heat resistant ferrous or non-ferrous alloys.
2. A coating of claim 1 wherein solid lubricating particles comprise at least one of the following: sulphides, sulphates or fluorides, advantageously one of the following: CaF2, BaF2, MoS2, WS2, FeS, MnS, h-BN (hexagonal boron nitride), CeF3, Ag2SO4, CaSo4, BaSo4, SrSo4.
3. A coating of claim 1 or 2, wherein the coating further comprises at least one of the following: carbide particles, nitride particles or boride particles advantageously tungsten carbide (WC), or titanium carbide (TiC), chromium carbide (Cr3C2).
4. A coating of any of claim 1 - 3, wherein the metal matrix is based on one of the following: cobalt or its alloys, nickel or its alloys.
5. A internal combustion engine valve, wherein the valve comprises a body, a head, and a contact surface on a valve head which is adapted to periodically enter into gas-sealing engagement with a valve seat, the contact surface comprising a PTA coating according to any of claims 1 - 4.
6. An internal combustion engine, wherein the valve seat surface comprises the PTA coating of any claim 1 - 4.
7. A marine vessel comprising a coating of any claim 1 - 4 on valve head contact surface or on valve seat surface of an internal combustion engine.
8. A method for manufacturing a PTA coating on valve seat surfaces characterized in that the method comprises steps of:
- providing a valve seat surface or a valve head surface as a substrate
- coating the substrate by Plasma-Transferred-Arc welding with a coating material comprising solid lubricating particles and matrix metal based on heat resistant ferrous or non-ferrous alloys.
9. A method of claim 8, wherein the matrix alloy powder and solid lubricant particles are mixed to form coating material powder before being inserted into a plasma torch.
10. A method of claim 8, wherein the matrix alloy powder and solid lubricant particles are provided as slurry and deposited on a substrate and then scanned with the plasma torch.
1 1 . A use of PTA coating prepared by method of claim 8 - 10 in a piston engine.
12. A use of PTA coating prepared by method of claim 8 - 10 in a marine vessel.
PCT/FI2014/050005 2014-01-03 2014-01-03 Plasma-transfer-arc-welding (pta) coating for use on valve seats, method for manufacturing, pta coating, and use of the pta coating on valve seat surfaces WO2015101699A1 (en)

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CN106637189A (en) * 2016-11-17 2017-05-10 中国科学院上海硅酸盐研究所 Metal ceramic coating and preparation method thereof
WO2018150080A1 (en) * 2017-02-20 2018-08-23 Wärtsilä Finland Oy Method of coating piston engine component and piston engine component
CN109504966A (en) * 2018-12-07 2019-03-22 中国兵器科学研究院宁波分院 A kind of preparation method of cylinder head vermicular cast iron surface abrasion resistance anti-friction coating
CN110270748A (en) * 2018-03-13 2019-09-24 江苏万恒铸业有限公司 The technique of mechanization plasma spray hard alloy valve sealing face
RU2714269C1 (en) * 2018-12-18 2020-02-13 Федеральное государственное бюджетное учреждение науки Институт металлургии и материаловедения им. А.А. Байкова Российской академии наук (ИМЕТ РАН) Cermet powder for plasma sputtering
CN111112812A (en) * 2019-12-30 2020-05-08 南通市电站阀门有限公司 Rapid welding method for sealing surface of plasma spray welding valve
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EP3872220A1 (en) * 2020-02-27 2021-09-01 Raytheon Technologies Corporation Self-lubricating, wear resistant piston sealing
CN113621957A (en) * 2021-07-06 2021-11-09 燕山大学 Preparation method of self-lubricating phase composite coating by laser cladding in-situ synthesis
CN115244280A (en) * 2020-03-11 2022-10-25 瓦锡兰芬兰有限公司 Method of configuring a gas exchange valve assembly in an internal combustion piston engine and gas exchange valve

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Cited By (10)

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Publication number Priority date Publication date Assignee Title
CN106637189A (en) * 2016-11-17 2017-05-10 中国科学院上海硅酸盐研究所 Metal ceramic coating and preparation method thereof
WO2018150080A1 (en) * 2017-02-20 2018-08-23 Wärtsilä Finland Oy Method of coating piston engine component and piston engine component
CN110270748A (en) * 2018-03-13 2019-09-24 江苏万恒铸业有限公司 The technique of mechanization plasma spray hard alloy valve sealing face
CN109504966A (en) * 2018-12-07 2019-03-22 中国兵器科学研究院宁波分院 A kind of preparation method of cylinder head vermicular cast iron surface abrasion resistance anti-friction coating
RU2714269C1 (en) * 2018-12-18 2020-02-13 Федеральное государственное бюджетное учреждение науки Институт металлургии и материаловедения им. А.А. Байкова Российской академии наук (ИМЕТ РАН) Cermet powder for plasma sputtering
EP3674019A1 (en) * 2018-12-25 2020-07-01 Kabushiki Kaisha Toshiba Valve
CN111112812A (en) * 2019-12-30 2020-05-08 南通市电站阀门有限公司 Rapid welding method for sealing surface of plasma spray welding valve
EP3872220A1 (en) * 2020-02-27 2021-09-01 Raytheon Technologies Corporation Self-lubricating, wear resistant piston sealing
CN115244280A (en) * 2020-03-11 2022-10-25 瓦锡兰芬兰有限公司 Method of configuring a gas exchange valve assembly in an internal combustion piston engine and gas exchange valve
CN113621957A (en) * 2021-07-06 2021-11-09 燕山大学 Preparation method of self-lubricating phase composite coating by laser cladding in-situ synthesis

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