EP0532331A1 - Revêtement coulé sur place à base de fer - Google Patents

Revêtement coulé sur place à base de fer Download PDF

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Publication number
EP0532331A1
EP0532331A1 EP92308259A EP92308259A EP0532331A1 EP 0532331 A1 EP0532331 A1 EP 0532331A1 EP 92308259 A EP92308259 A EP 92308259A EP 92308259 A EP92308259 A EP 92308259A EP 0532331 A1 EP0532331 A1 EP 0532331A1
Authority
EP
European Patent Office
Prior art keywords
aluminium
grooves
liner
sleeve
low pressure
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Granted
Application number
EP92308259A
Other languages
German (de)
English (en)
Other versions
EP0532331B1 (fr
Inventor
Robert Anthony Martin
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.)
Ford Werke GmbH
Ford France SA
Ford Motor Company Ltd
Ford Motor Co
Original Assignee
Ford Werke GmbH
Ford France SA
Ford Motor Company Ltd
Ford Motor Co
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 Werke GmbH, Ford France SA, Ford Motor Company Ltd, Ford Motor Co filed Critical Ford Werke GmbH
Publication of EP0532331A1 publication Critical patent/EP0532331A1/fr
Application granted granted Critical
Publication of EP0532331B1 publication Critical patent/EP0532331B1/fr
Anticipated expiration legal-status Critical
Expired - Lifetime legal-status Critical Current

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D19/00—Casting in, on, or around objects which form part of the product
    • B22D19/0009—Cylinders, pistons
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D19/00—Casting in, on, or around objects which form part of the product
    • B22D19/0081—Casting in, on, or around objects which form part of the product pretreatment of the insert, e.g. for enhancing the bonding between insert and surrounding cast metal

Definitions

  • This invention relates to cast-in-place iron based liners and a method of casting an aluminium cylinder block having such liners
  • Metallurgical bonding although it is not thoroughly understood, has proved unsuccessful possibly because the lighter weight metal, such as aluminium, has a strong tendency to chill and form an oxide film at the interface in at least some minor zone.
  • complex castings such as aluminium engine blocks having intricately-shaped water jackets and a number of thin- walled cylinder walls, the ability to keep the aluminium at a sufficiently high temperature, at 100% of the interface with a liner, is extremely difficult. As the aluminium fully solidifies, it moves away (shrinks) and thus delaminates in at least such minor zone. As a result, there is a degraded heat transfer characteristic for the block that prevents such technique from being used commercially. At best, there is only 80-85% lay-up of the aluminium along the iron-based liner interface wall.
  • the interfacing surface of the casting iron liners has been roughened by spiny protrusions when such liners are initially formed by casting; such protrusions act as longitudinal and circumferential mechanical bonds when aluminium is cast under high pressure (die-cast) therearound.
  • High pressure is always required to move the aluminium across such protrusions and still achieve lay-up of aluminium against the original outer wall of the liner.
  • the machined smooth wall of the liner becomes the valleys between the protrusions. Because of the need for quick high pressure mould filling to prevent premature freezing, such technique is impractical when casting aluminium engine blocks by low pressure (in the range of 2-5 psi), and mould filling times take an average of one-half minute.
  • the invention is a cast-in-place liner construction useful in low pressure casting of hollow aluminium parts, the construction is characterised by an iron-based cylindrical body having a surface thereof imprinted with a repeating pattern of crossed groups of relief grooves, each groove forming a helix along such surface, the spacing between such grooves and the depth of such grooves being uniformly controlled to permit the grooves to act as molten aluminium runners during low pressure casting of the aluminium that facilitates laying-up of the aluminium along the entire surface.
  • the grooves advantageously will have a depth in the range of .02-.04 inch; the spacing between grooves is advantageously .20-.30 inch; and a width for each of such grooves in the range of .02-.04 inch.
  • the included angle between intersecting groups of grooves is in the range of 35-55°.
  • the imprinted surface is the outer cylindrical surface of the liner while the inner cylindrical surface thereof is smooth.
  • a second aspect of this invention is a casting method deploying such liner, the method comprising: (a) imprinting a cylindrical surface of a sleeve that is designed to interface with cast aluminium thereagainst, the imprinting providing a quilted pattern of shallow grooves, such grooves being sized and spaced to promote transfer of molten aluminium during low pressure filling of the mould containing such sleeve; and (b) planting the liner in such mould and introducing aluminium thereagainst at a low pressure to form a desired aluminium casting.
  • the imprinting may be carried out by machining the prefabricated sleeve or by imprinting indentations in the sleeve during rolling or fabrication of such sleeve.
  • Casting in place of iron cylinder liners in an aluminium cylinder block is considered routine when the block is produced by high pressure die casting. Molten metal is injected under high pressure and for a short period of time to facilitate the lay-up of the aluminium against the iron liner. However, for casting processes such as gravity or low pressure where mould filling occurs over a relatively long period and takes place with little or no pressure, the casting-in-place of liners is considered extremely difficult.
  • This invention provides for a unique quilted pattern of grooving on the surface of the iron liner that is to interface with the aluminium, such pattern promoting the flow of molten aluminium against the iron cylinder bore liner surface to overcome the problem of chilling and accompanying oxide formation.
  • the iron-based liner 20 has a cylindrical body B provided with an outer surface 10 and an inner cylindrical surface 11, and a pattern C imprinted onto the outer cylindrical surface 10, which pattern is comprised of crossed groups 12 and 13 of relief grooves 14.
  • the grooves are effective to uniformly act as molten aluminium runners during low pressure casting to facilitate laying-up of the aluminium along the entire cylindrical surface 10.
  • the grooves create a diamond-shaped pattern as criss-crossed, the lateral spacing 15 between adjacent grooves being on the order of .20-.30 inch, the depth 16 of each of the grooves being in the range of .02-.04 inch, and the width 17 of each of the grooves being desirably in the range of .02-.04 inches.
  • the included angle 18 between intersecting or crossing grooves is in the range of 35-55°.
  • the pattern is imprinted on the outer cylindrical surface by either machining such pattern as the sleeve is rotated, or the pattern may be formed by indentations in the liner during rolling or casting of the liner itself.
  • the grooves in each of the groups are helical about the outer surface of the liner; this is advantageous when placing the liner in an oblique position such as shown in Figure 4 for a V-shaped configuration aluminium block. In such application, one set of grooves will be somewhat horizontal with respect to a vertical plane 21 and the other set of grooves will be closer to the vertical plane as they wrap around the outer surface of the liner.
  • a casting method deploying such liners comprises: (a) imprinting a cylindrical surface of a iron-based sleeve designed to interface with a cast aluminium thereagainst, the sleeve having a quilted pattern of shallow grooves with the grooves sized and spaced to promote transfer of molten aluminium during a low pressure filling of a mould containing the sleeve; and (b) planting the liner in such mould and introducing aluminium thereagainst at a low pressure to form the desired aluminium casting.
  • the pressure employed in such method is in the range of 2-5 psi and the temperature of the molten aluminium will be in the range of 1275°F. Due to the pattern of the grooves and their critical sizing, the molten aluminium will not drop below a fluid temperature during filling of the mould and will not prematurely freeze in migrating throughout all of the interstices of the cylindrical surface of the liner.
  • the grooves are defined to have a depth in excess of .04 inch, there will be a tendency for the aluminium to freeze or form a miniscus characteristic of problems associated with the prior art. If the depth of the grooves is less than .02, there is little likelihood that a molten aluminium runner effect will be created. If groove spacing is greater than .3 inch, the ability to lay aluminium throughout the normal cylindrical surface is hindered, whereas a spacing between grooves of less than .20 inch will create difficulty in filling all the grooves with molten aluminium because of the lack of pressure driving the aluminium through such an increased maze of grooves. The ultimate effect of this invention achieves essentially 100% lay-up of aluminium against the iron- based liner after the completion of the low pressure casting technique. By “lay-up” it is herein meant: the amount of intimate contact between the outer surface of the iron liner and the aluminium barrel that surrounds the liner.

Landscapes

  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Cylinder Crankcases Of Internal Combustion Engines (AREA)
  • Pistons, Piston Rings, And Cylinders (AREA)
EP19920308259 1991-09-12 1992-09-10 Revêtement coulé sur place à base de fer Expired - Lifetime EP0532331B1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US75813191A 1991-09-12 1991-09-12
US758131 1991-09-12

Publications (2)

Publication Number Publication Date
EP0532331A1 true EP0532331A1 (fr) 1993-03-17
EP0532331B1 EP0532331B1 (fr) 1996-12-18

Family

ID=25050625

Family Applications (1)

Application Number Title Priority Date Filing Date
EP19920308259 Expired - Lifetime EP0532331B1 (fr) 1991-09-12 1992-09-10 Revêtement coulé sur place à base de fer

Country Status (4)

Country Link
EP (1) EP0532331B1 (fr)
CA (1) CA2077187A1 (fr)
DE (1) DE69216018T2 (fr)
MX (1) MX9204697A (fr)

Cited By (10)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP0826444A1 (fr) * 1996-08-27 1998-03-04 Daimler-Benz Aktiengesellschaft Ebauche en métal léger utilisé comme pièce d'insertion dans un autre objet en métal léger et procédé de traitement de surface de cette ébauche
WO1999043457A1 (fr) * 1998-02-25 1999-09-02 Daimlerchrysler Ag Procede pour produire une ebauche de chemise de cylindre, a couler dans le carter en alliage leger d'un moteur a piston alternatif
EP1002602A1 (fr) * 1998-11-21 2000-05-24 VAW alucast GmbH Dispositif et procédé pour la fabrication d'un bloc moteur
EP1110644A1 (fr) * 1999-12-15 2001-06-27 Teipi Industry Co., Ltd. Insert coulé à rugosité controlée pour moulage avec insert et produit fabriqué par ce procédé de moulage
DE10012787A1 (de) * 2000-03-16 2001-09-20 Volkswagen Ag Verfahren zur Herstellung von Leichtmetallgussteilen mit eingegossenen Buchsen und Buchse zum Eingiessen
EP1504833A4 (fr) * 2002-05-13 2005-07-20 Honda Motor Co Ltd Coquille interne de moulage de fonte et procede de production de celle-ci
US7172011B2 (en) 2001-05-25 2007-02-06 Mahle Gmbh Method for the production of a lost-foam casting model for a light metal cylinder liner
WO2011131712A1 (fr) * 2010-04-23 2011-10-27 Rheinisch-Westfälische Technische Hochschule Aachen Pièce coulée composite hybride métallique
US20160252042A1 (en) * 2015-02-27 2016-09-01 Avl Powertrain Engineering, Inc. Cylinder Liner
US11499499B1 (en) 2021-10-05 2022-11-15 Brunswick Corporation Marine engines, cylinder liners for marine engines, and methods and assemblies for forming marine engines

Families Citing this family (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE102017214732A1 (de) * 2017-08-23 2019-02-28 Bayerische Motoren Werke Aktiengesellschaft Verfahren zur Auslegung eines Bauteil- oder Werkstoffverbunds
DE102018122407A1 (de) * 2018-09-13 2020-03-19 Bergmann Automotive GmbH Zylinderlaufbuchse für einen Kolbenmotor

Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
FR450434A (fr) * 1912-11-11 1913-03-25 Anthelme Girel Procédé de fabrication de cylindres de moteurs, en acier avec chemise de fonte brasée
GB873012A (en) * 1959-01-02 1961-07-19 Aluminum Co Of America Cast bimetallic articles
US3069209A (en) * 1958-07-16 1962-12-18 Alfred F Bauer Method of bonding a bi-metallic casting
US3401026A (en) * 1966-01-19 1968-09-10 Gen Motors Corp Method of forming a bimetallic article
EP0491978A1 (fr) * 1989-12-15 1992-07-01 Audi Ag Bloc cylindre pour moteur à explosion

Patent Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
FR450434A (fr) * 1912-11-11 1913-03-25 Anthelme Girel Procédé de fabrication de cylindres de moteurs, en acier avec chemise de fonte brasée
US3069209A (en) * 1958-07-16 1962-12-18 Alfred F Bauer Method of bonding a bi-metallic casting
GB873012A (en) * 1959-01-02 1961-07-19 Aluminum Co Of America Cast bimetallic articles
US3401026A (en) * 1966-01-19 1968-09-10 Gen Motors Corp Method of forming a bimetallic article
EP0491978A1 (fr) * 1989-12-15 1992-07-01 Audi Ag Bloc cylindre pour moteur à explosion

Cited By (15)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US6074763A (en) * 1996-08-27 2000-06-13 Daimlerchrysler Ag Light metal part activation for casting with another light metal part
EP0826444A1 (fr) * 1996-08-27 1998-03-04 Daimler-Benz Aktiengesellschaft Ebauche en métal léger utilisé comme pièce d'insertion dans un autre objet en métal léger et procédé de traitement de surface de cette ébauche
US6286583B1 (en) 1996-08-27 2001-09-11 Daimlerchrysler Ag Two part light metal coating and method of making same
US6286210B1 (en) 1998-02-25 2001-09-11 Daimlerchrysler Ag Method for producing a cylinder liner blank to be cast into a light-alloy crankcase of a reciprocating engine
WO1999043457A1 (fr) * 1998-02-25 1999-09-02 Daimlerchrysler Ag Procede pour produire une ebauche de chemise de cylindre, a couler dans le carter en alliage leger d'un moteur a piston alternatif
EP1002602A1 (fr) * 1998-11-21 2000-05-24 VAW alucast GmbH Dispositif et procédé pour la fabrication d'un bloc moteur
EP1110644A1 (fr) * 1999-12-15 2001-06-27 Teipi Industry Co., Ltd. Insert coulé à rugosité controlée pour moulage avec insert et produit fabriqué par ce procédé de moulage
DE10012787A1 (de) * 2000-03-16 2001-09-20 Volkswagen Ag Verfahren zur Herstellung von Leichtmetallgussteilen mit eingegossenen Buchsen und Buchse zum Eingiessen
DE10012787B4 (de) * 2000-03-16 2008-04-10 Volkswagen Ag Verfahren zur Herstellung von Leichtmetallgussteilen mit eingegossenen Buchsen
US7172011B2 (en) 2001-05-25 2007-02-06 Mahle Gmbh Method for the production of a lost-foam casting model for a light metal cylinder liner
EP1504833A4 (fr) * 2002-05-13 2005-07-20 Honda Motor Co Ltd Coquille interne de moulage de fonte et procede de production de celle-ci
US7226667B2 (en) 2002-05-13 2007-06-05 Honda Giken Kogyo Kabushiki Kaisha Cast-iron insert and method of manufacturing same
WO2011131712A1 (fr) * 2010-04-23 2011-10-27 Rheinisch-Westfälische Technische Hochschule Aachen Pièce coulée composite hybride métallique
US20160252042A1 (en) * 2015-02-27 2016-09-01 Avl Powertrain Engineering, Inc. Cylinder Liner
US11499499B1 (en) 2021-10-05 2022-11-15 Brunswick Corporation Marine engines, cylinder liners for marine engines, and methods and assemblies for forming marine engines

Also Published As

Publication number Publication date
DE69216018D1 (de) 1997-01-30
CA2077187A1 (fr) 1993-03-13
EP0532331B1 (fr) 1996-12-18
MX9204697A (es) 1993-03-01
DE69216018T2 (de) 1997-04-03

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