Piston Surface Treatment via Powder Injection
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Solution Overview
Problem
Current methods for improving the mechanical strength of internal combustion pistons face challenges such as surface flaws, increased manufacturing costs, and inadequate strength at high temperatures, while also struggling to enhance combustion efficiency and reduce harmful exhaust gases, especially during engine startup.
Innovation Solution
A surface treatment method involving the injection of powders with reinforcing and photocatalytic elements, such as Ti, Sn, and Zr, which are diffused and penetrated into the piston surface to form a modified layer with improved mechanical strength and photocatalytic functionality, capable of functioning at room temperature without UV irradiation, thereby enhancing strength, abrasion resistance, and combustion efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If shot peening treatment is performed to improve mechanical strength, then strength reliability is improved, but additional treatment steps and equipment complexity are required
Solution Approach 1:
The patent combines the shot peening process with photocatalytic material application into a single integrated treatment step. The photocatalytic particles are embedded in the surface layer during the same process that applies compressive stresses, eliminating the need for separate treatment stages and reducing overall process complexity while maintaining strength improvement benefits.
Solution Approach 2:
The treatment process simultaneously achieves multiple functions: it provides mechanical strengthening through shot peening, imparts photocatalytic activity for combustion efficiency enhancement, and creates a modified surface layer with improved properties. This multi-functionality reduces the number of separate treatments needed.
2Use of energy by moving object
If photocatalytic materials are applied to improve combustion efficiency, then fuel consumption is reduced, but additional treatment steps are required
Solution Approach 1:
The photocatalytic material application is merged with the shot peening process, so that both the mechanical strengthening and photocatalytic functionality are achieved in a single treatment operation. This eliminates the need for separate photocatalytic coating steps and reduces overall process complexity.
Solution Approach 2:
The surface treatment process simultaneously provides mechanical strengthening and photocatalytic activity, allowing one treatment step to serve multiple purposes: improving fuel consumption through photocatalysis while also enhancing structural integrity through shot peening.
3Strength
If surface treatment is performed to repair surface flaws, then strength is improved, but treatment time is increased
Solution Approach 1:
The surface flaw repair function is combined with the shot peening and photocatalytic material application in a single integrated process. The compressive stresses from shot peening simultaneously close surface flaws and embed the photocatalytic particles, reducing treatment time while maintaining strength improvement.
Solution Approach 2:
The treatment process continues to provide useful action throughout the single operational step: shot peening particles simultaneously repair surface flaws, apply compressive stresses, and embed photocatalytic materials, eliminating idle time between separate treatment operations.
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
The method effectively improves the mechanical strength of internal combustion pistons at a reasonable cost, repairs surface flaws, and enhances combustion efficiency and reduces harmful exhaust gases immediately after engine startup, maintaining strength even at high temperatures.
Implementation Method 1
injection powders containing a reinforcing element improving the strength of the alloy by being diffused and penetrated in the alloy comprising the piston
Implementation Method 2
injection powders containing a photocatalytic element exhibiting a photocatalytic function by oxidation... capable of enhancing combustion efficiency and reducing harmful emissions at room temperature without the need for heat treatment or UV irradiation
Data Source
AI summary
An internal combustion piston comprises a modified layer produced by a surface treatment including injecting injection powders having a diameter of 20 μm to 400 μm and containing a reinforcing element to be collided with a surface of the internal combustion piston obtained by casting and forging by injecting at an injection speed of 80 m/s or more or at an injection pressure of 0.3 MPa or more, the reinforcing element improving a strength of an alloy comprising the piston when being diffused and penetrated in the alloy, wherein by the surface treatment, oxides generated on the surface of the piston by the casting and forging are removed, and surface flaws generated on the surface are repaired, whereby the modified layer is formed to have a uniformly fine-grained metal microstructure which contains the reinforcing element in the injection powders diffused and penetrated in the vicinity of the surface of the piston and an alloy element of the alloy comprising the piston.