Cylinder Crankcase Thermal Spraying Process
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The existing process for producing engines with thermally sprayed cylinder bearing surfaces faces challenges in achieving good bonding of the sprayed layer while being economically viable and minimizing scrap rates, with high equipment and production costs.
Innovation Solution
A process involving casting of cylinder crankcases with oversized dimensions, followed by thermal spraying of Fe-containing materials, high-pressure blasting for roughening and cleaning, and subsequent machining to final dimensions, using a plasma or arc wire spraying process, and employing a baffle surface to stabilize the jet and improve reproducibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If thermal spraying process is used to coat cylinder bores, then bonding of the sprayed layer is improved, but production costs and equipment outlay increase
Solution Approach 1:
The patent employs disposable consumable layers on templates that are replaced after each use rather than maintaining expensive reusable equipment. The template with consumable layers serves as a cost-effective alternative to high-cost thermal spraying equipment while achieving adequate bonding quality for production purposes.
Solution Approach 2:
The patent introduces templates with consumable layers as an intermediary medium between the coating process and the cylinder bore. This intermediary approach allows for controlled material application and improves bonding without requiring direct investment in expensive thermal spraying equipment, thereby reducing production costs while maintaining layer bonding quality.
2Adaptability or versatility
If templates with exchangeable consumable layers are used for coating and roughening, then processing flexibility is improved, but device complexity increases
Solution Approach 1:
The patent divides the template into segments with exchangeable consumable layers that can be independently replaced. This segmentation allows for flexible adaptation to different processing requirements by changing only the necessary consumable layers rather than replacing the entire template system, thereby managing device complexity while maintaining processing flexibility.
Solution Approach 2:
The patent enables parameter changes by exchanging consumable layers with different properties on the template. This allows adjustment of processing parameters such as roughness and coating characteristics without modifying the underlying template structure, achieving versatility while keeping the overall device complexity manageable through standardized template design.
3Manufacturing precision
If multiple separate operations (cleaning, degreasing, roughening) are performed, then processing quality is improved, but production time and costs increase
Solution Approach 1:
The patent merges multiple separate operations (cleaning, degreasing, and roughening) into a single integrated process step using the template with consumable layers. This consolidation maintains processing quality by ensuring all operations are performed in sequence on the same surface without repositioning, while simultaneously reducing production time by eliminating intermediate handling and setup between operations.
Solution Approach 2:
The patent performs preliminary actions by pre-equipping the template with consumable layers that perform multiple functions (cleaning, degreasing, roughening) in one application. This preliminary preparation of the surface with all necessary treatments integrated into the template system eliminates the need for separate subsequent operations, thereby maintaining quality while reducing overall production time and costs.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This process enhances the bonding of the sprayed layer, reduces production costs, minimizes scrap rates, and optimizes equipment usage by integrating cleaning, degreasing, and machining in a single step, while maintaining high precision and reproducibility.
Implementation Method 1
The bearing surface layer is applied, after preprocessing of the cylinder bores or of the cylinder crankcase, by way of a thermal spraying process and, in particular, a plasma and/or arc wire spraying process
Implementation Method 2
The bearing surface layer is applied, after preprocessing of the cylinder bores or of the cylinder crankcase, by way of a thermal spraying process and, in particular, a plasma and/or arc wire spraying process
Implementation Method 3
the surface of the cylinder bores is roughened. It is preferable for roughening to be carried out by way of a fluid which is blasted onto the walls at a high pressure (several hundred to several thousand bar). In this case, as in the case, for example, of sand blasting, it is also possible for solid particles, such as sand or corundum, to be added to the blasting fluid
Data Source
AI summary
In a process for processing cylinder crankcases having sprayed cylinder barrels, in which process a cylinder crankcase is cast, those surfaces of the subsequent cylinder barrels which are to be thermally coated are roughened, the cylinder barrels are coated by a thermal spraying process, and the cylinder barrels are remachined to final dimensions. After the thermal spraying process, coating material is at least partially removed from the crankshaft-side part of the cylinder crankcase.