无缸套全铝合金气缸体缸孔内壁涂层的制备及性能研究
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摘要
为了研究铝合金气缸孔内壁涂层对发动机轻量化及摩擦磨损等性能方面的优势。采用SUMEBore内孔等离子喷涂工艺制备全铝合金气缸孔内壁涂层,对涂层微观结构、结合强度、显微硬度等性能进行了分析测试,测试结果表明涂层的微观组织均匀,与基体结合良好,平均结合强度达到35 MPa以上,硬度在374 HV0.3左右,与传统的镶入铸铁缸套的某直列四缸气缸体相比,实现降重2.5 kg。在干摩擦和润滑两种条件下,利用CETR UMT-3多功能摩擦磨损测试仪对涂层样块及传统的铸铁缸套样块进行摩擦磨损对比试验,结果表明在干摩擦和润滑2种条件下,涂层的摩擦磨损性能明显优于传统的铸铁缸套,缸孔表面性能得到显著改善。
引文
[1]李汶哲.汽车企业节能新技术评价及油耗目标优化方法[D].长沙:湖南大学, 2015.
[2]郑晖,赵曦雅.汽车轻量化及铝合金在现代汽车生产中的应用[J].锻压技术, 2016(2):1-6.
[3]蔡其刚.铝合金在汽车车体上的应用现状及发展趋势探讨[J].轻工科技, 2009, 12(1):28-29.
[4]王智文.汽车轻量化技术发展现状初探[J].汽车工艺与材料,2009,(2):1-5.
[5]刘黎明,肖金坤,徐海峰,等.热喷涂汽车发动机气缸内壁涂层的研究进展[J].表面技术, 2017, 46(2):68-76.
[6] ZORN T, NENTWICH G, PICHLER A. Plasma coating to replace cast iron cylinder liners in production[R].SAE Technical Paper, 2012.
[7] ERNST P, BARBEZAT, GERARD. Thermal spray applications in powertrain contribute to the saving of energy and material resources[J]. Surface&Coatings Technology, 2008, 202(18):4428-4431.
[8]肖立新,沈婕,高峰,等.发动机汽缸内壁新型耐磨涂层研究[J].热喷涂技术, 2012, 4(1):32-35.
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[10] BARBEZAT G, WUEST G. Advantages for automotive industry of plasma spray coating of Ai-Si cast alloy cylinder bores[J]. Surface Engineering, 1998, 14(2):113-116.
[11]李增荣.铝制内燃机缸体内壁铁基涂层的制备及摩擦学特性的研究[D].沈阳:沈阳工业大学, 2016.
[12]王海斗,何鹏飞,陈书赢,等.内孔热喷涂技术的研究现状与展望[J].中国表面工程, 2018, 31(05):20-44.
[13] ERNST P, DISTLER B, BARBEZAT G. SUMEBorecoating solution for cylinder surfaces[J], Thermal Spray Bulletin, 2011, 4(1), 26-29.
[14] MORAWITZ U, MEHRING J, SCHRAMM L. Benefits of thermal spray coatings in internal combustion engines,with specific view on friction reduction and thermal management[R]. SAE Technical Paper, 2013.
[15] BARBEZAT G. Advanced thermal spray technology and coating for lightweight engine blocks for the automotive industry[J]. Surface&Coatings Technology, 2005, 200(5-6):1990-1993.
[16] ERNST P. SUMEBore-The coating solution to protect cylinder liner surfaces[J]. SAE International Journal of Engines, 2012, 5(4):1802-1811.
[17] ERNST P,朱炳全.保护气缸套工作表面的SUMEBore涂层解决方案[J],国外内燃机, 2013, 45(6):58-62.
[18] ERNST P, DISTLER B. Optimizing the cylinder running surface/piston system of internal combustion engines towards lower emissions[R]. SAE Technical Paper, 2012.
[19] KUMAGAI H. Section flow improvement of plasma spray cylinder in outboard motor[R]. SAE Technical Paper,2013.
[20] BOBZIN K, ERNST F, ZWICK J, et al. Coating Bores of Light Metal Engine Blocks with a Nanocomposite Material using the Plasma Transferred Wire Arc Thermal Spray Process[J]. Journal of Thermal Spray Technology,2008, 17(3):344-351.
[21] MANZAT A, KILLINGER A, GADOW R, et al.超音速火焰喷涂气缸内壁涂层及其固有孔隙的益处[J].热喷涂技术, 2012, 4(2):57-64.
[22] AKALIN O, NEWAZ G M, DURGA V, et al. Frictional Characteristics of Plasma Spray Coated Cylinder Bores[R]. SAE Technical Paper, 1999.
[2]郑晖,赵曦雅.汽车轻量化及铝合金在现代汽车生产中的应用[J].锻压技术, 2016(2):1-6.
[3]蔡其刚.铝合金在汽车车体上的应用现状及发展趋势探讨[J].轻工科技, 2009, 12(1):28-29.
[4]王智文.汽车轻量化技术发展现状初探[J].汽车工艺与材料,2009,(2):1-5.
[5]刘黎明,肖金坤,徐海峰,等.热喷涂汽车发动机气缸内壁涂层的研究进展[J].表面技术, 2017, 46(2):68-76.
[6] ZORN T, NENTWICH G, PICHLER A. Plasma coating to replace cast iron cylinder liners in production[R].SAE Technical Paper, 2012.
[7] ERNST P, BARBEZAT, GERARD. Thermal spray applications in powertrain contribute to the saving of energy and material resources[J]. Surface&Coatings Technology, 2008, 202(18):4428-4431.
[8]肖立新,沈婕,高峰,等.发动机汽缸内壁新型耐磨涂层研究[J].热喷涂技术, 2012, 4(1):32-35.
[9] BARBEZAT G, KELLER S, WUEST G. Internal plasma spray process for cylinder bores in automotive industry[C].ITSC 1998, 963-974.
[10] BARBEZAT G, WUEST G. Advantages for automotive industry of plasma spray coating of Ai-Si cast alloy cylinder bores[J]. Surface Engineering, 1998, 14(2):113-116.
[11]李增荣.铝制内燃机缸体内壁铁基涂层的制备及摩擦学特性的研究[D].沈阳:沈阳工业大学, 2016.
[12]王海斗,何鹏飞,陈书赢,等.内孔热喷涂技术的研究现状与展望[J].中国表面工程, 2018, 31(05):20-44.
[13] ERNST P, DISTLER B, BARBEZAT G. SUMEBorecoating solution for cylinder surfaces[J], Thermal Spray Bulletin, 2011, 4(1), 26-29.
[14] MORAWITZ U, MEHRING J, SCHRAMM L. Benefits of thermal spray coatings in internal combustion engines,with specific view on friction reduction and thermal management[R]. SAE Technical Paper, 2013.
[15] BARBEZAT G. Advanced thermal spray technology and coating for lightweight engine blocks for the automotive industry[J]. Surface&Coatings Technology, 2005, 200(5-6):1990-1993.
[16] ERNST P. SUMEBore-The coating solution to protect cylinder liner surfaces[J]. SAE International Journal of Engines, 2012, 5(4):1802-1811.
[17] ERNST P,朱炳全.保护气缸套工作表面的SUMEBore涂层解决方案[J],国外内燃机, 2013, 45(6):58-62.
[18] ERNST P, DISTLER B. Optimizing the cylinder running surface/piston system of internal combustion engines towards lower emissions[R]. SAE Technical Paper, 2012.
[19] KUMAGAI H. Section flow improvement of plasma spray cylinder in outboard motor[R]. SAE Technical Paper,2013.
[20] BOBZIN K, ERNST F, ZWICK J, et al. Coating Bores of Light Metal Engine Blocks with a Nanocomposite Material using the Plasma Transferred Wire Arc Thermal Spray Process[J]. Journal of Thermal Spray Technology,2008, 17(3):344-351.
[21] MANZAT A, KILLINGER A, GADOW R, et al.超音速火焰喷涂气缸内壁涂层及其固有孔隙的益处[J].热喷涂技术, 2012, 4(2):57-64.
[22] AKALIN O, NEWAZ G M, DURGA V, et al. Frictional Characteristics of Plasma Spray Coated Cylinder Bores[R]. SAE Technical Paper, 1999.