Method for improving aluminizing service time and bonding quality of piston insert ring

Abstract

The invention discloses a method for improving the aluminizing service time and bonding quality of a piston insert ring, which comprises the following steps: S1, smelting an aluminizing liquid alloy material, and correspondingly increasing the manganese content by 0.4% when the iron content is increased by 1% during smelting to obtain an aluminizing liquid with the iron content less than 6%; and S2, the insert ring is subjected to aluminizing treatment, and after the insert ring is preheated, shaking of the insert ring in aluminizing liquid is achieved through gas vibration. According to the method, the aluminum manganese 20 intermediate alloy is added, the manganese element is rapidly added into the aluminizing liquid in the production interstitial process to refine the iron phase, and the continuity of the production process is guaranteed. And finally, due to the action of the manganese element, the thick needle iron phase in the ZL102 aluminizing liquid which is not used any more is refined, direct recycling can be achieved, and the production cost is further reduced.

Description

Technical Field

[0001] This invention relates to the field of aluminizing of piston rings during the piston casting process, and specifically to a method for improving the service life and bonding quality of aluminizing piston rings. Background Technology

[0002] The ring-insulated aluminum piston, by inserting high-nickel austenitic wear-resistant rings into the piston ring groove area (usually the first ring groove), not only maintains the lightweight characteristics of aluminum pistons, but also has the wear-resistant properties of cast iron piston ring grooves, greatly improving the service life of the ring grooves.

[0003] With the development of internal combustion engines and environmental protection, piston rings are being used more and more, becoming the mainstream piston product. The Alfin Process is commonly used in piston ring casting. This method is a special process for the metallurgical bonding of cast iron piston rings with the aluminum alloy piston matrix. Through aluminizing the piston rings, an aluminum-iron alloy transition layer (FeAl3, Fe2Al5) is formed on the surface of the cast iron piston ring, achieving a metallurgical bond between it and the poured molten aluminum alloy.

[0004] Currently, aluminum-silicon alloys are commonly used for aluminizing piston rings, with ZL102 being a frequently used material. The rings are made of high-nickel austenitic cast iron with a nickel content of 13.5%-17.5%. The process involves preheating the shot-blasted rings and immersing them in ZL102 molten aluminum for 4-8 minutes. Then, the rings are quickly placed into the piston mold, and molten aluminum is poured into the mold to completely encapsulate the rings and achieve a metallurgical bond.

[0005] Throughout the production process, the ZL102 aluminum melt initially contains less than 0.2% iron. As the insert rings are immersed in the aluminum melt, the iron content gradually increases. When the iron content reaches approximately 4%, the iron phase integrated into the aluminizing melt is a coarse, needle-like iron phase, significantly reducing fluidity. This leads to an increase in the viscosity of the aluminized layer of the insert rings, causing solidification in the portion before the insert rings are completely enveloped by the aluminum melt in the piston body, resulting in insert ring adhesion defects. To ensure product quality, the iron content of the aluminizing melt for insert rings is required to be below 4%. Taking a 102mm diameter piston insert ring as an example, approximately 2500 piston blanks are produced from one batch of 250 kg of aluminizing melt, with an insert adhesion defect rate of about 0.3%. If the iron content exceeds 4%, the defect rate from insert ring adhesion flaw detection will increase significantly. Furthermore, the ZL102 aluminizing melt that is no longer used cannot be directly reused due to the very coarse needle-like iron phase. Summary of the Invention

[0006] The purpose of this invention is to provide a method for improving the service life and bonding quality of piston ring aluminizing, so as to solve the technical problems of high scrap rate of ring bonding and the inability to directly reuse aluminizing liquid in the prior art.

[0007] To achieve the above objectives, the present invention provides the following technical solution: This invention provides a method for improving the service life and bonding quality of aluminized piston rings, comprising the following steps: S1. Aluminizing liquid alloy material smelting: during smelting, for every 1% increase in iron content, the manganese content increases by 0.4% accordingly, resulting in an aluminizing liquid with an iron content of less than 6%. S2. The inlay ring undergoes aluminum diffusion treatment. After the inlay ring is preheated, it is vibrated in the aluminum diffusion liquid by gas vibration.

[0008] Furthermore, S1 also includes the following steps: S11. Refining treatment of aluminum infiltration liquid: Pour 60g-90g of Pyroflux GR DR212 refining agent into the aluminum infiltration liquid vortex along the edge of the vortex and refine it at 720℃-760℃. The degassing time for aluminum infiltration liquid is 10 minutes. S12. Aluminum liquid standing: After the aluminum liquid is refined, let it stand for 10 minutes. Use a density equivalent meter to test the quality of the aluminum liquid. If the density equivalent DI value is ≤0.6, clean the slag and open the package for use.

[0009] Furthermore, S2 specifically includes the following sub-steps: S21. Preheating the bead setting: Preheat the bead setting at 200℃-300℃ for 60-120 minutes; S22, Aluminizing the Ring: After preheating, the ring is placed on the aluminizing hook, and then the aluminizing hook is placed on the aluminizing frame with a gas vibrator. The ring is shaken in the aluminizing liquid by gas vibration; Aluminizing temperature: 720℃-740℃; Aluminizing time: 4 minutes-8 minutes.

[0010] Furthermore, the aluminizing liquid is obtained by processing ZL102 aluminum liquid. Specifically, when the iron content in the ZL102 aluminum liquid reaches 2%, aluminum-manganese 20 master alloy is added and melted, and the manganese content in the aluminizing liquid reaches 0.4%. The aluminizing liquid is then refined. ① Refining temperature: 720-760℃; ② 60g-90g of Pyroflux GR DR212 refining agent is poured into the aluminum liquid vortex along the edge of the vortex for refining; ③ The aluminum liquid refining and degassing time is 10 minutes. After refining, the aluminizing temperature is maintained at 720℃-740℃; the aluminizing time is 4-8 minutes. The aluminizing process for the ring insert is then used normally.

[0011] Furthermore, the specific process for obtaining the aluminizing solution is as follows: When the iron content in the ZL102 aluminum liquid reaches 3%, an aluminum-manganese 20 master alloy is added again for melting, bringing the manganese content in the aluminizing solution to 0.8%. The aluminizing solution is then refined. ① Refining temperature: 720-760℃; ② 60g-90g of Pyroflux GR DR212 refining agent is poured into the aluminum liquid vortex along the edge of the vortex for refining; ③ The aluminum liquid refining and degassing time is 10 minutes. After refining, the aluminizing temperature is maintained at 720℃-740℃; the aluminizing time is 4-8 minutes. The aluminizing process for the ring insert is then used normally.

[0012] Furthermore, the specific process for obtaining the aluminizing solution is as follows: When the iron content in the ZL102 aluminum liquid reaches 4%, an aluminum-manganese 20 master alloy is added again for melting, bringing the manganese content in the aluminizing solution to 1.2%. The aluminizing solution is then refined. ① Refining temperature: 720-760℃; ② 60g-90g of Pyroflux GR DR212 refining agent is poured into the aluminum liquid vortex along the edge of the vortex for refining; ③ The aluminum liquid refining and degassing time is 10 minutes. After refining, the aluminizing temperature is maintained at 720℃-740℃; the aluminizing time is 4-8 minutes. The aluminizing process for the ring insert is then used normally.

[0013] Furthermore, the specific process for obtaining the aluminizing solution is as follows: When the iron content in the ZL102 aluminum liquid reaches 5%, an aluminum-manganese 20 master alloy is added again for melting, bringing the manganese content in the aluminizing solution to 1.6%. The aluminizing solution is then refined. ① Refining temperature: 720-760℃; ② 60g-90g of Pyroflux GR DR212 refining agent is poured into the aluminum liquid vortex along the edge of the vortex for refining; ③ The aluminum liquid refining and degassing time is 10 minutes. After refining, the aluminizing temperature is maintained at 720℃-740℃; the aluminizing time is 4-8 minutes. The aluminizing process for the ring insert is then used normally.

[0014] Furthermore, ZL102 aluminum melt is initially used when the iron content is <0.2%. As the iron content gradually increases to 2%, aluminum-manganese 20 master alloy is gradually added. The manganese element refines the iron phase in the aluminum melting melt, reducing its viscosity. Similarly, for every 1% increase in iron content, the manganese content increases by 0.4%. This process ensures normal use of the aluminum melting melt when the iron content reaches 6%.

[0015] Based on the above technical solution, the embodiments of the present invention can produce at least the following technical effects: (1) The method provided by this invention for improving the service life and bonding quality of aluminizing piston rings involves gradually adding manganese as the iron content gradually increases to 2%, refining the iron phase in the aluminizing solution, and reducing the viscosity of the aluminizing solution. For every 1% increase in iron content, the manganese content increases by 0.4%, which allows aluminizing solutions with an iron content of less than 6% to be used normally.

[0016] (2) The method provided by the present invention for improving the service time and bonding quality of piston ring aluminizing is to add aluminum-manganese 20 intermediate alloy, and to quickly add manganese to the aluminizing liquid during the production gap process to refine the iron phase, thereby ensuring the continuity of the production process.

[0017] (3) The method provided by the present invention to improve the service time and bonding quality of piston ring aluminizing is that the iron phase in the ZL102 aluminizing liquid that is no longer used is refined due to the effect of manganese, and can be directly reused, further reducing production costs. Detailed Implementation

[0018] Various exemplary embodiments of the present invention will now be described in detail. This detailed description should not be considered as a limitation of the present invention, but rather as a more detailed description of certain aspects, features, and embodiments of the present invention.

[0019] It should be understood that the terminology used in this invention is merely for describing particular embodiments and is not intended to limit the invention. Furthermore, with respect to numerical ranges in this invention, it should be understood that each intermediate value between the upper and lower limits of the range is also specifically disclosed. Every smaller range between any stated value or intermediate value within a stated range, and any other stated value or intermediate value within said range, is also included in this invention. The upper and lower limits of these smaller ranges may be independently included or excluded from the range.

[0020] Unless otherwise stated, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art described herein.

[0021] Various modifications and variations can be made to the specific embodiments described in this specification without departing from the scope or spirit of the invention, as will be apparent to those skilled in the art. Other embodiments derived from this specification will also be obvious to those skilled in the art. This specification and embodiments are merely exemplary.

[0022] The Pyroflux GR DR212 refining agent was purchased from Pyroflux High Temperature Materials Ltd.

[0023] Example 1 ZL102 aluminum liquid was initially used when the iron content was <0.2%. As the iron content gradually increased to 2%, aluminum-manganese 20 master alloy was gradually added. At the end, the Fe content was 5.92% and the Mn content was 1.88%. Aluminizing liquid refining treatment: Pour 60g of Pyroflux GR DR212 refining agent along the edge of the vortex into the aluminizing liquid vortex and refine it at 740℃. The aluminum liquid refining and degassing time is 10 minutes. Aluminum liquid settling: After the aluminum liquid is refined, let it stand for 10 minutes. Use a density equivalent meter to test the quality of the aluminum liquid. If the density equivalent DI value is ≤0.6, then remove the slag and open the package for use.

[0024] Preheating of the bead setting: Preheat the bead setting at 250°C for 100 minutes; Aluminizing the ring: After preheating, the ring is placed on the aluminizing hook, and then the aluminizing hook is placed on the aluminizing frame with a gas vibrator. The ring is shaken in the aluminizing liquid by gas vibration; aluminizing temperature: 740℃; aluminizing time: 8 minutes.

[0025] Example 2 ZL102 aluminum liquid was initially used when the iron content was <0.2%. As the iron content gradually increased to 2%, aluminum-manganese 20 master alloy was gradually added. At the end, the Fe content was 6.05% and the Mn content was 1.95%. Aluminizing liquid refining treatment: Pour 60g of Pyroflux GR DR212 refining agent along the edge of the vortex into the aluminizing liquid vortex and refine it at 740℃. The aluminum liquid refining and degassing time is 10 minutes. Aluminum liquid settling: After the aluminum liquid is refined, let it stand for 10 minutes. Use a density equivalent meter to test the quality of the aluminum liquid. If the density equivalent DI value is ≤0.6, then remove the slag and open the package for use.

[0026] Preheating of the bead setting: Preheat the bead setting at 250°C for 100 minutes; Aluminizing the ring: After preheating, the ring is placed on the aluminizing hook, and then the aluminizing hook is placed on the aluminizing frame with a gas vibrator. The ring is shaken in the aluminizing liquid by gas vibration; aluminizing temperature: 740℃; aluminizing time: 8 minutes.

[0027] Example 3 ZL102 aluminum liquid was initially used when the iron content was <0.2%. As the iron content gradually increased to 2%, aluminum-manganese 20 master alloy was gradually added. At the end, the Fe content was 5.89% and the Mn content was 2.05%. Aluminizing liquid refining treatment: Pour 60g of Pyroflux GR DR212 refining agent along the edge of the vortex into the aluminizing liquid vortex and refine it at 740℃. The aluminum liquid refining and degassing time is 10 minutes. Aluminum liquid settling: After the aluminum liquid is refined, let it stand for 10 minutes. Use a density equivalent meter to test the quality of the aluminum liquid. If the density equivalent DI value is ≤0.6, then remove the slag and open the package for use.

[0028] Preheating of the bead setting: Preheat the bead setting at 250°C for 100 minutes; Aluminizing the ring: After preheating, the ring is placed on the aluminizing hook, and then the aluminizing hook is placed on the aluminizing frame with a gas vibrator. The ring is shaken in the aluminizing liquid by gas vibration; aluminizing temperature: 740℃; aluminizing time: 8 minutes.

[0029] The specific results are shown in Table 1: The test data in the table above shows that, according to the method of the invention, the service life of the aluminizing solution for the piston ring is doubled, and the bonding quality is guaranteed.

[0030] The above description is only a preferred embodiment of the present invention. It should be noted that those skilled in the art can make several modifications and improvements without departing from the inventive concept of the present invention, and these all fall within the protection scope of the present invention.

Claims

1. A method for improving the service life and bonding quality of aluminized piston rings, characterized in that, Includes the following steps: S1. Aluminizing liquid alloy material smelting: during smelting, for every 1% increase in iron content, the manganese content increases by 0.4% accordingly, resulting in an aluminizing liquid with an iron content of less than 6%. S2. The inlay ring undergoes aluminum diffusion treatment. After the inlay ring is preheated, it is vibrated in the aluminum diffusion liquid by gas vibration.

2. The method for improving the service life and bonding quality of aluminized piston rings according to claim 1, characterized in that, S1 further includes the following steps: S11. Refining treatment of aluminum infiltration liquid: Pour 60g-90g of Pyroflux GR DR212 refining agent into the aluminum infiltration liquid vortex along the edge of the vortex and refine it at 720℃-760℃. The degassing time for aluminum infiltration liquid is 10 minutes. S12. Aluminum liquid standing: After the aluminum liquid is refined, let it stand for 10 minutes. Use a density equivalent meter to test the quality of the aluminum liquid. If the density equivalent DI value is ≤0.6, clean the slag and open the package for use.

3. The method for improving the service life and bonding quality of aluminized piston rings according to claim 1, characterized in that, S2 specifically includes the following sub-steps: S21. Preheating the bead setting: Preheat the bead setting at 200℃-300℃ for 60-120 minutes; S22, Aluminizing the Ring: After preheating, the ring is placed on the aluminizing hook, and then the aluminizing hook is placed on the aluminizing frame with a gas vibrator. The ring is shaken in the aluminizing liquid by gas vibration; Aluminizing temperature: 720℃-740℃; Aluminizing time: 4 minutes-8 minutes.

4. The method for improving the service life and bonding quality of aluminized piston rings according to claim 1, characterized in that, The aluminizing solution is obtained by processing ZL102 aluminum liquid. Specifically, when the iron content in the ZL102 aluminum liquid reaches 2%, aluminum-manganese 20 master alloy is added and melted. When the manganese content in the aluminizing solution reaches 0.4%, the aluminizing solution is refined.

5. The method for improving the service life and bonding quality of aluminized piston rings according to claim 4, characterized in that, The specific process for obtaining the aluminizing solution is as follows: when the iron content in the ZL102 aluminum liquid reaches 3%, aluminum-manganese 20 intermediate alloy is added again for melting, and the manganese content in the aluminizing solution reaches 0.8%. The aluminizing solution is then refined.

6. The method for improving the service life and bonding quality of aluminized piston rings according to claim 5, characterized in that, The specific process for obtaining the aluminizing solution is as follows: when the iron content in the ZL102 aluminum liquid reaches 4%, aluminum-manganese 20 intermediate alloy is added again for melting, and the manganese content in the aluminizing solution reaches 1.2%. The aluminizing solution is then refined.

7. The method for improving the service life and bonding quality of aluminized piston rings according to claim 6, characterized in that, The specific process for obtaining the aluminizing solution is as follows: when the iron content in the ZL102 aluminum liquid reaches 5%, aluminum-manganese 20 intermediate alloy is added again for melting, and the manganese content in the aluminizing solution reaches 1.6%. The aluminizing solution is then refined.

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