U.S. patent application number 14/134855 was filed with the patent office on 2014-04-17 for method for making an arrangement consisting of a cast part and a cast-in component.
This patent application is currently assigned to MAHLE International GmbH. The applicant listed for this patent is MAHLE International GmbH. Invention is credited to Gerhard BUCHER.
Application Number | 20140102659 14/134855 |
Document ID | / |
Family ID | 46342686 |
Filed Date | 2014-04-17 |
United States Patent
Application |
20140102659 |
Kind Code |
A1 |
BUCHER; Gerhard |
April 17, 2014 |
METHOD FOR MAKING AN ARRANGEMENT CONSISTING OF A CAST PART AND A
CAST-IN COMPONENT
Abstract
A method for making an arrangement consisting of a cast part and
a cast-in component composed of a metallic material. The cast-in
component is composed of a metallic material that has a
galvanically applied nickel layer. The layer is applied by
positioning the cast-in component in an electrolyte bath and
applying the coating on at least part of the surface of the
component. The cast-in component is then positioned in a casting
mold and a cast part is casted around the cast-in part.
Inventors: |
BUCHER; Gerhard; (Eppingen,
DE) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
MAHLE International GmbH |
Stuttgart |
|
DE |
|
|
Assignee: |
MAHLE International GmbH
Stuttgart
DE
|
Family ID: |
46342686 |
Appl. No.: |
14/134855 |
Filed: |
December 19, 2013 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
13325521 |
Dec 14, 2011 |
|
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14134855 |
|
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Current U.S.
Class: |
164/69.1 ;
164/75 |
Current CPC
Class: |
C25D 3/12 20130101; Y10T
428/12451 20150115; B22D 19/0009 20130101; Y10T 428/12944 20150115;
C25D 7/00 20130101; Y10T 428/12937 20150115; B22D 19/0081 20130101;
B22D 19/0027 20130101; C25D 5/14 20130101; Y10T 428/12472 20150115;
C25D 15/00 20130101 |
Class at
Publication: |
164/69.1 ;
164/75 |
International
Class: |
B22D 19/00 20060101
B22D019/00 |
Foreign Application Data
Date |
Code |
Application Number |
Dec 18, 2010 |
DE |
10 2010 055 162.7 |
Claims
1. A method for making an arrangement consisting of a cast part,
and a cast-in component, around which the cast part is cast,
comprising the following steps: preparing a cast-in component
composed of steel or cast iron or a light-metal alloy, positioning
the cast-in component in an electrolyte bath and applying a coating
composed of a galvanically applied nickel layer on at least part of
the surface of said cast-in component which is intended to be
casted in a casting process, positioning the coated cast-in part in
a casting mould for said cast part, and casting the cast part
around the cast-in part.
2. The method according to claim 1, wherein the nickel layer is
applied with a deposition rate of 1.0 .mu.m to 1.4 .mu.m per
minute.
3. The method according to claim 1, where the nickel layer is
applied at a current-density of 6 A/dm.sup.2.
4. The method according to claim 1, where the nickel layer is
applied at a bath temperature of 60.degree. C.
5. The method according to claim 1, where the nickel layer is
applied at a pH value of the electrolyte bath of 2.5 to 3.0.
6. The method according to claim 1, where the nickel layer is
applied using an electrolyte comprising an aqueous solution of
nickel sulfate.
7. The method according to claim 1, wherein the electrolyte bath
contains at least one solid component.
8. The method according to claim 1, wherein the coating after
deposition of the nickel layer has a layer thickness of 3 .mu.m to
80 .mu.m.
9. The method according to claim 1, wherein the coating furthermore
contains at least one of solids dispersed in the layer
10. The method according to claim 1, wherein the coating
furthermore comprises a galvanically deposited carrier layer
composed of copper.
11. The method according to claim 1, wherein the coating is applied
to a surface region of the cast-in component having a rough depth
of 5 .mu.m to 1,400 .mu.m.
12. The method according to claim 11, wherein the coating is
applied to a surface region of the cast-in component that has been
cast in finished manner or pre-machined by cutting.
13. The method according to claim 11, wherein the coating is
applied to a blasted surface region.
14. The method according to claim 1, wherein the cast-in component
is a cylinder liner and the cast part is a crankcase of an engine
block.
15. The method according to claim 1, wherein the cast-in component
is a hoop and the cast part is a break drum.
16. The method according to claim 1, wherein the cast-in component
is a ring carrier and the cast part is a piston for an internal
combustion engine.
Description
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This is a divisional of U.S. patent application Ser. No.
13/325,521, filed on Dec. 14, 2011, which claims priority under 35
U.S.C. .sctn.119 of German Application No. 10 2010 055 162.7 filed
on Dec. 18, 2010, the disclosures of which are incorporated by
reference.
BACKGROUND OF THE INVENTION
[0002] The present invention relates to a method of making an
arrangement consisting of a cast part and a cast-in component
having a coating composed of a metallic coating material.
[0003] In machine construction, in particular, components
frequently have to be provided with a coating that can fulfill
various tasks, for example as a tribological coating or as a
connection layer between two components. An example is the
production of cast parts composed of metals or metal alloys, in
which other components, namely cast-in components, composed of a
metallic material that differs from that of the cast part, are cast
in. This relates, for example, to cast parts composed of
light-metal alloys, in the form of crankcases for internal
combustion engines. Cylinder liners are cast into these crankcases,
which liners generally consist of iron casting materials, steels,
or tribologically suitable light-metal alloys, for example having a
high silicon content and/or intermetallic phases. Another example
is a hoop composed of steel or cast iron, which is cast into a
brake drum composed of a light-metal alloy.
[0004] In this connection, a firm bond between the material of the
cast-in component and the material of the cast part is required, in
order to ensure sufficient mechanical anchoring of the cast-in
component in the cast part and good heat transfer between the
cast-in component and the cast part. However, the materials used
for the cast-in component and the cast part, respectively, are
generally incompatible and do not form a firm bond with one
another. For this reason, the cast-in component is generally
provided with a coating on its surface that stands in contact with
the cast part, which coating adheres well to the cast-in component,
for one thing, and allows an alloy connection to be formed by the
material of the cast part.
[0005] Frequently, thermally spray-coated layers are used as
coatings, not only for cast-in components, but also for other
components; these layers are applied to the surface of the
component by means of one of the known spray-coating methods (for
example wire flame spray-coating, powder flame spray-coating, arc
wire spray-coating, plasma spray-coating, HVOF spray-coating, cold
gas spray-coating, and more). Such a coating is described in DE 10
2005 027 828 A1, for example.
[0006] However, all the thermal spray-coating processes have in
common that the thermally spray-coated layers adhere to the
component solely on the basis of physical bonds. Thermally
spray-coated layers are furthermore generally not free of embedded
oxides and porosities. All this is expressed in the adhesion
tensile strength of thermally spray-coated layers, which is
determined using the adhesion tensile test and generally lies in
the range of 10 to 50 N/mm.sup.2, depending on the material and
production quality (in the case of wire flame spray-coating and arc
wire spray-coating, generally at 10 to 30 N/mm.sup.2). There is
therefore the risk that the thermally spray-coated layer tears off
under great stress. Because of the great investment requirement for
thermal spray-coating and process monitoring, thermally
spray-coated layers represent a cost-intensive solution.
[0007] Coatings are also known that are obtained by means of
dipping the component to be coated into a zinc or zinc-based alloy
melt. In this connection, an immersion layer is generally formed,
which adheres with sufficient strength after it hardens.
[0008] However, these coatings are not reliably suited for cast-in
components, because the layer can come loose from the cast-in
component during the casting-in process, on the basis of the
thermal expansion of the zinc, and furthermore, it is weakened at
the boundary region to the cast-in material, by means of a pore
seam composed of Kirkendall pores.
SUMMARY OF THE INVENTION
[0009] The present invention is therefore based on the task of
making available a coating for a cast-in component as well as a
cast-in component that is coated on at least part of its surface,
whereby a firm bond between the coating obtained and the component,
particularly a good adhesion tensile strength, is supposed to be
achievable in cost-advantageous manner.
[0010] The solution consists of a coating that consists of
galvanically applied nickel, and in a cast-in component that is
provided with a coating in the form of a galvanically applied
nickel layer on at least part of its surface.
[0011] The coating according to the invention and the cast-in
component according to the invention are characterized in that a
firm bond between the surface of the cast-in component and the
coating is produced in particularly simple and cost-advantageous
manner. Nickel bonds easily to other metallic materials. It alloys
with cast iron, for example, and forms a connection system with
aluminum and its alloys. The thermal expansion coefficient of
nickel amounts to 13.3.times.10.sup.-6 K.sup.-1, and therefore lies
between the values for cast iron (12.0.times.10.sup.-6 K.sup.-1)
and aluminum block alloys (21.0.times.10.sup.-6 K.sup.-1). Despite
these differences, which still exist, no weakening of the bond
between the galvanically applied nickel layer and the cast-in
component needs to be feared on the basis of thermal expansion of
the coated cast-in component, during the casting-in process.
[0012] The coating according to the invention therefore adheres to
the cast-in component much more firmly than thermally spray-coated
layers. Furthermore, any desired metallic materials can be used for
the cast-in component, because the galvanically applied nickel
layer can form intermetallic bonds or alloys with the material of
the cast-in component.
[0013] The cast-in component according to the invention can be
processed further in usual manner, and is suitable for many
purposes. It can be cast into another cast part, for example, in a
manner known to a person skilled in the art, by means of gravity
casting, low-pressure casting, die-casting, squeeze casting. If
necessary, the component coated according to the invention can be
preheated.
[0014] A layer thickness of 3 .mu.m to 80 .mu.m has proven to be
practical. Layer thicknesses of 5 .mu.m to 50 .mu.m are preferred,
with which a satisfactory balance between good shear strength and
low material consumption is achieved. A layer thickness of 15 .mu.m
is particularly preferred.
[0015] Depending on the area of application, the coating according
to the invention can furthermore contain solids dispersed in it,
such as, for example, reinforcement fibers composed of metal or
plastic or pyrogenic silicas. In this way, the stability of the
coating according to the invention can be further increased.
Finally, a thin copper layer can also be galvanically deposited
between the surface of the cast-in component and the coating
according to the invention.
[0016] The coating according to the invention can be applied to
surfaces having a broad spectrum of properties, and therefore can
be used in particularly versatile manner. For example, surfaces
having a rough depth of 5 .mu.m to 1,400 .mu.m are suitable. The
surfaces can be cast in finished form or pre-machined by cutting
them. The surfaces can also be blasted before the coating according
to the invention is applied, for example with abrasives such as
glass beads, corundum sand, or steel grit.
[0017] The cast-in component can consist, for example, of steel or
cast iron, malleable cast iron, or a light-metal alloy such as, for
example, an aluminum-based or magnesium-based alloy. The cast-in
component can be formed originally by means of casting, forging,
rolling, or by way of powder metallurgy. Typical examples of
materials that are suitable for the cast-in component are aluminum
alloys having up to 30 wt.-% silicon and/or up to 4 wt.-% copper
and/or up to 4 wt.-% magnesium and/or up to 4 wt.-% nickel;
aluminum-zinc alloys or copper-aluminum-nickel alloys (aluminum
bronze); copper-tin alloys having up to 14 wt.-% tin (cast tin
bronze); copper-zinc alloys having up to 44 wt.-% zinc;
copper-nickel alloys or copper-nickel-iron alloy; steel from the
group of the highly alloyed austenitic or ferritic steels; alloys
on the basis of titanium.
[0018] A typical example of use of the present invention is
cylinder liners that are provided with the coating according to the
invention and cast into a crankcase of an engine block. Another
example is hoops that are provided with the coating according to
the invention and cast into a brake drum, or furthermore for ring
carriers that are cast into a piston.
DETAILED DESCRIPTION OF THE EMBODIMENTS
[0019] Exemplary embodiments of the present invention will be
explained in greater detail below.
[0020] A component is provided with a coating on its surface. The
component can have any desired shape, for example flat,
ring-shaped, non-uniform, etc. Examples are a cylinder liner for an
internal combustion engine, or a hoop for a brake drum. Before
being coated, the surface of the component can be cleaned with
corundum sand, for example. The surface can be cast in finished
manner and be comparatively smooth. However, the surface can also
be pre-machined by cutting, or roughened, for example produced
using the rough-casting method.
[0021] To prepare the coating, a smoothly lathed cylinder liner for
the crankcase of an internal combustion engine composed of cast
iron was closed off with screw-on plastic caps, in order to prevent
deposition of nickel in the liner interior. The current contact can
also be passed out of the cylinder liner by way of the screw
connection. The outer mantle surface as well as the face surfaces,
on the head side and foot side, of the cylinder liner were first
degreased using ultrasound, and then anodically degreased. After
each work step, etching took place, and rinsing took place multiple
times. This method of preparation is familiar to a person skilled
in the art.
[0022] The coating according to the invention can be applied in the
form of a matte nickel plating or a shiny nickel plating, whereby
the less complicated matte nickel plating is completely sufficient.
Nickel sulfate in aqueous solution was used as an electrolyte, as
the main component, for example on the basis of the Watt nickel
electrolyte. If necessary, solids can also be contained in it, such
as reinforcement fibers or pyrogenic silicas, which disperse into
the coating that forms during the production process.
[0023] The layer thickness of the coating according to the
invention is controlled in known manner, by way of the parameters
current density, bath temperature, and pH of the electrolyte.
Deposition rates of 1.0 .mu.m to 1.4 .mu.m per minute have proven
themselves. A typical deposition rate of 1.2 .mu.m per minute for
the cylinder liner coated in the exemplary embodiment is obtained,
for example, at a current density of 6 A/dm.sup.2, a bath
temperature of 60.degree. C., and a pH of the electrolyte of 2.5 to
3.0. It is practical if the electrode is configured in such a
manner that it surrounds the cylinder liner in the form of a
cylinder mantle, in order to achieve a particularly uniform
coating.
[0024] The finished, coated cylinder liner was cast into a
crankcase. The material of the crankcase was a block alloy of the
AlSi8Cu3 type. Before being cast in, the cylinder liner according
to the invention was heated to approximately 100.degree. C., for
practical reasons, particularly in order to remove traces of
moisture.
[0025] The good adhesion of the coating according to the invention
on the cast-in component is expressed, among other things, in the
shear strength, whereby the cylinder liner galvanically coated with
nickel on the outer mantle surface, according to the invention,
already yielded values of 50 N/mm.sup.2 when cast into the
crankcase, using gravity casting.
* * * * *