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EP1258540B1 - Mask member for placing on an engine body during the thermal coating of the internal cylinder bores and process using this masking member - Google Patents

Mask member for placing on an engine body during the thermal coating of the internal cylinder bores and process using this masking member Download PDF

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Publication number
EP1258540B1
EP1258540B1 EP02405024A EP02405024A EP1258540B1 EP 1258540 B1 EP1258540 B1 EP 1258540B1 EP 02405024 A EP02405024 A EP 02405024A EP 02405024 A EP02405024 A EP 02405024A EP 1258540 B1 EP1258540 B1 EP 1258540B1
Authority
EP
European Patent Office
Prior art keywords
masking device
protective masking
coating
mask
protective
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.)
Expired - Lifetime
Application number
EP02405024A
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German (de)
French (fr)
Other versions
EP1258540A1 (en
Inventor
Ralph Herber
Peter Zürcher
Gérard BARBEZAT
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.)
Oerlikon Metco AG
Original Assignee
Sulzer Metco AG
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Filing date
Publication date
Application filed by Sulzer Metco AG filed Critical Sulzer Metco AG
Publication of EP1258540A1 publication Critical patent/EP1258540A1/en
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Publication of EP1258540B1 publication Critical patent/EP1258540B1/en
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Classifications

    • C—CHEMISTRY; METALLURGY
    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
    • C23C4/12—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge characterised by the method of spraying
    • C23C4/14—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge characterised by the method of spraying for coating elongate material
    • C23C4/16—Wires; Tubes
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05B—SPRAYING APPARATUS; ATOMISING APPARATUS; NOZZLES
    • B05B12/00—Arrangements for controlling delivery; Arrangements for controlling the spray area
    • B05B12/16—Arrangements for controlling delivery; Arrangements for controlling the spray area for controlling the spray area
    • B05B12/20—Masking elements, i.e. elements defining uncoated areas on an object to be coated
    • C—CHEMISTRY; METALLURGY
    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
    • C23C4/01—Selective coating, e.g. pattern coating, without pre-treatment of the material to be coated
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05B—SPRAYING APPARATUS; ATOMISING APPARATUS; NOZZLES
    • B05B13/00—Machines or plants for applying liquids or other fluent materials to surfaces of objects or other work by spraying, not covered by groups B05B1/00 - B05B11/00
    • B05B13/06—Machines or plants for applying liquids or other fluent materials to surfaces of objects or other work by spraying, not covered by groups B05B1/00 - B05B11/00 specially designed for treating the inside of hollow bodies
    • B05B13/0627—Arrangements of nozzles or spray heads specially adapted for treating the inside of hollow bodies
    • B05B13/0636—Arrangements of nozzles or spray heads specially adapted for treating the inside of hollow bodies by means of rotatable spray heads or nozzles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05B—SPRAYING APPARATUS; ATOMISING APPARATUS; NOZZLES
    • B05B7/00—Spraying apparatus for discharge of liquids or other fluent materials from two or more sources, e.g. of liquid and air, of powder and gas
    • B05B7/16—Spraying apparatus for discharge of liquids or other fluent materials from two or more sources, e.g. of liquid and air, of powder and gas incorporating means for heating or cooling the material to be sprayed
    • B05B7/22—Spraying apparatus for discharge of liquids or other fluent materials from two or more sources, e.g. of liquid and air, of powder and gas incorporating means for heating or cooling the material to be sprayed electrically, magnetically or electromagnetically, e.g. by arc
    • B05B7/222—Spraying apparatus for discharge of liquids or other fluent materials from two or more sources, e.g. of liquid and air, of powder and gas incorporating means for heating or cooling the material to be sprayed electrically, magnetically or electromagnetically, e.g. by arc using an arc

Definitions

  • the invention relates to a mask for placing on an engine block in the thermal coating of cylinder bores embedded therein according to claim 1 and a method for thermal coating of cylinder bores of engine blocks using a mask according to claim 13.
  • the cylinder bores or their walls are provided with a tread layer or it liners are inserted into the cylinder bores, which may also be provided with a tread layer.
  • the application of such tread layers is usually carried out by means of thermal coating methods, in particular rotating Plasmatrons have proven to apply the layer.
  • the problem with the application of such tread layers is u.a. in that the entire tread should be made homogeneous.
  • thermal coating device Since a thermal coating apparatus such as a plasma spraying needs a certain start-up time until a homogeneous coating jet is generated, the thermal coating device must be activated prior to insertion into the cylinder bore, otherwise an irregular initial layer is formed within the cylinder bore. When activating the thermal coating device outside the cylinder bore to be coated, however, there is the danger that machined surfaces of the engine block are undesirably "contaminated" by the coating jet
  • a cover template is known, which is intended to be placed on the cylinder crankshaft housing of an internal combustion engine.
  • This cover template has a plurality of through openings, via which a coating tool can be introduced into the interior of the cylinder crankshaft housing.
  • the cover template is designed so that all other
  • the cover template has an exact flat underside, which is intended to rest on the already flat ground cylinder head surface of the cylinder crankcase. It is understood that such a cover template is expensive to manufacture. In addition, it is not universally applicable, since it must be adapted to the extent of the cylinder crankshaft housing, so that all other areas of the cylinder crankshaft housing are covered. In addition, the underside must be reworked from time to time, so that the flatness is maintained.
  • a mask is known, which is brought from the bottom of an engine block ago to the lower end of the cylinder surface.
  • the mask is formed in two parts, with oblique parting surfaces, so that the two parts against each other shifted through a narrow point of the crankcase can be inserted into the engine block.
  • the interior of the engine block, namely the crankcase to be protected from contamination during thermal coating of the cylinder surfaces.
  • the US Pat. No. 5,573,814 describes an inflatable mask, by means of which contamination of the cylinder crankcase by a coating device can be prevented.
  • the inflatable body is made of fiberglass material and partially coated with silicone, with the geometric shape of the mask varying in an inflated or deflated condition.
  • This inflatable mask can be combined with a flange cuff.
  • the inflatable mask is according to US Pat. No. 5,573,814 reusable by a coating applied on its surface.
  • the object of the invention is therefore to propose a cost-effective, reusable and easy-to-use mask, which allows activation of the thermal coating device outside the cylinder bore to be coated, without the engine block or the environment is contaminated by coating particles, the mask not the entire Cover the top of the engine block and where a high quality of the applied layer is to be ensured.
  • a different approach is chosen in the present case.
  • a hollow cylindrical design and matched to the diameter of the cylinder bore to be coated mask is proposed.
  • Such a trained mask does not cover the entire surface of the engine block to be coated, but only an annular area around the cylinder bore to be coated around. On this circular area around the cylinder bore to be coated, the mask rests on the engine block.
  • Such a hollow cylindrical mask has u.a. the advantage that it is very simple and inexpensive to manufacture and can be achieved on the engine block in the region of the cylinder bore to be coated by the small contact surface safe, gap-free edition of the mask.
  • the height of the mask is selected to be greater than the maximum vertical extent of the coating jet when the coating device is inserted into the mask.
  • the coating head of the coating device can be introduced into the mask in the inactive state and activated therein.
  • the quality of the coating process can be ensured in general since there is no appreciable contamination of the upper side of the engine block by the coating jet, since no coating particles emerge from the mask.
  • a regular coating of the cylinder surface is achieved, since the coating process is started outside the cylinder bore and a continuous layer transition from the mask to the cylinder bore can take place.
  • Claims 11 to 18 also claim methods for thermally coating cylinder bores of engine blocks using masks designed according to the invention.
  • Fig. 1 a cross section through an engine block with a first embodiment of a mask according to the invention
  • Fig. 2 a cross section through the engine block with a second embodiment of a mask according to the invention
  • Fig. 3 a cross section through the engine block with a third embodiment of a mask according to the invention.
  • FIG. 1 From the FIG. 1 is schematically a shown in cross-section engine block 1 of a series engine, a patch on its top 7 mask 4 and the front part 8 of a coating device can be seen.
  • a coating device for example, a plasma spray gun with a rotating coating head 9 can be provided.
  • the engine block 1 is provided with a plurality of cylinder bores, from which representation only one cylinder bore 2 can be seen.
  • the mask 4 fixed coaxially to the cylinder bore 2 on the upper side of the engine block 1 consists of a tubular outer part 5 and a substantially hollow cylindrical insert 6.
  • the mask 4 and its insert 6 are matched to the diameter of the cylinder bore 2 to be coated. In the present case, the inner diameter of the insert 6 is slightly larger than the diameter of the cylinder bore 2.
  • the insert 6 Since the insert 6 is coated with the inner diameter changes with increasing duration of use; ie the inner diameter of the insert 6 decreases with increasing duration of use. In the present case, this insert 6 is designed as a wear part, which is usually removed after one to ten applications. By providing an insert 6, it is not necessary to replace the entire mask 4, but only the insert 6. This is preferably made from a metallic, ceramic or organic material or a combination thereof. The height of the mask 4 is normally between 20 and 40 mm. It is in any case chosen so that the coating jet 10, as shown, fully impinges on the inside of the mask 4 when the coating head 9 is inserted into the mask 4.
  • the coating head 9 By first introducing the coating head 9 into the mask 4 and only then activating it, it is possible to ensure that no appreciable contamination of the surroundings by coating particles is produced. After the coating device is activated, the head 9 can be slowly retracted into the cylinder bore 2. As a result, the cylinder bore 2 or its walls 3 is coated continuously and there is no irregular initial layer.
  • the insert 6 is preferably inserted loosely in the outer part 5, so that it is movable relative to the outer part 5 in the vertical direction.
  • the insert 6 is provided with a stop in the form of a circumferential shoulder 6a on the top.
  • the insert 6 is preferably formed slightly higher than the outer part 5, so that it rests with the end face on the engine block 1 - and not with the Shoulder 6a on the outer part 5 of the mask - when the mask 6 is placed on the engine block 1. This ensures, on the one hand, a gap-free support of the insert 6 on the engine block 1 and, on the other hand, the insert 6 can be replaced in the simplest manner.
  • the mask can also be adapted very quickly to different bore diameters.
  • the mask 4 can be provided with positioning means for aligning and / or fixing with respect to the engine block 1.
  • positioning means for aligning and / or fixing with respect to the engine block 1.
  • pins or bolts may be provided, which engage in sunken in the engine block 1 holes. Both the positioning means as well as the recessed into the engine block 1 holes are not shown in the present case.
  • the coating is preferably applied by plasma spraying, high-speed flame spraying, arc spraying, flame spraying, inert gas plasma spraying or inert gas arc spraying.
  • Fig. 2 shows a cross section through the engine block with a second embodiment of a mask 4a.
  • This is in turn tubular, ie hollow cylindrical, with no use is provided.
  • the mask 4a is designed in such a way that the layers 11, 12 applied on the inside by the coating device can be mechanically removed if necessary, for example by unscrewing. The removal of the layer can also be done by blasting with abrasive powders such as corundum (Al2O3) or silicon carbide (SiC).
  • the inner diameter of the mask 4a is preferably slightly larger than the diameter of the cylinder bore 2, so that the layers 11, 12 are not complete, d. H. must be removed to the inner diameter of the mask 4a, which would hardly be possible anyway without damage or weakening of the mask 4a. With reference to the present example, it would be sufficient if the inner layer 11 were removed.
  • Fig. 3 shows a further Austjngs example of the invention.
  • a mask arrangement is provided, which consists of a plurality of masks, which are interconnected by a frame 13.
  • the distance between the individual masks is adapted to the distance between cylinder bores of the engine block.
  • the individual mask 4 or its insert 6 lies substantially only on an annular surface along the cylinder bore 2 to be coated.
  • air is passed through the cylinder bore located in the active coating process during the coating process by the air is sucked off on the underside of the cylinder bore via means not shown.
  • Extraction of the air has the advantage that the coating particles not applied to the wall of the cylinder bore can be reliably removed downwards and can not be deposited on the upper side of the engine block .
  • the content of oxygen bound in the layer can be influenced in a defined manner by means of a targeted air flow.
  • the provision of an inventively designed mask 4, 4a brings with it an advantage in that prevail by acting as an extension of the cylinder bore 2 mask within the cylinder bore 2 more favorable flow conditions than without mask, which in turn manifests itself in a more uniform quality of the applied layer.
  • the two embodiments shown are not to be considered as exhaustive.
  • the distance between the masks is adjusted to the distance between the cylinder bores of the engine block, which are not directly adjacent cylinder bores are coated simultaneously, but in a four-cylinder in-line engine, for example, first the holes 1 and 3 and then the holes 2 and 4.

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Plasma & Fusion (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Materials Engineering (AREA)
  • Physics & Mathematics (AREA)
  • Metallurgy (AREA)
  • Organic Chemistry (AREA)
  • Coating By Spraying Or Casting (AREA)
  • Cylinder Crankcases Of Internal Combustion Engines (AREA)
  • Details Or Accessories Of Spraying Plant Or Apparatus (AREA)
  • Physical Vapour Deposition (AREA)
  • Chemical Vapour Deposition (AREA)

Abstract

Mask (4) for placing on an engine block (1) during thermal coating of cylinder bores (2) has a hollow cylindrical shape and agrees with the diameter of the bores to be coated. Preferred Features: The mask has a tubular outer part (5) and an insert (6). The mask and the insert lie on a circular surface along the cylinder bores to be coated. The insert protrudes over the outer part on the lower side. The insert is made of a metallic, ceramic and/or organic material.

Description

Die Erfindung betrifft eine Maske zum Aufsetzen auf einen Motorblock beim thermischen Beschichten von darin eingelassenen Zylinderbohrungen gemäss dem Anspruch 1 sowie ein Verfahren zum thermischen Beschichten von Zylinderbohrungen von Motorblöcken unter Verwendung einer Maske gemäss dem Anspruch 13.The invention relates to a mask for placing on an engine block in the thermal coating of cylinder bores embedded therein according to claim 1 and a method for thermal coating of cylinder bores of engine blocks using a mask according to claim 13.

Bei der Herstellung von Verbrennungsmotoren finden heutzutage vermehrt Motorblöcke aus Leichtmetall Verwendung. Da Leichtmetall jedoch grundsätzlich keine hohe Abrieb und Verschleissfestigkeit aufweist, werden die Zylinderbohrungen bzw. deren Wandungen mit einer Laufflächenschicht versehen oder es werden Laufbüchsen in die Zylinderbohrungen eingesetzt, welche ggf. auch noch mit einer Laufflächenschicht versehen werden. Das Aufbringen solcher Laufflächenschichten erfolgt zumeist mittels thermischen Beschichtungsverfahren, wobei sich insbesondere rotierende Plasmatrons zum Aufbringen der Schicht bewährt haben. Die Problematik beim Aufbringen solcher Laufflächenschichten besteht u.a. darin, dass die gesamte Lauffläche homogen ausgebildet sein soll. Da eine thermische Beschichtungsvorrichtung wie beispielsweise eine Plasmaspritzvorrichtung eine bestimmte Anlaufzeit braucht, bis ein homogener Beschichtungsstrahl erzeugt wird, muss die thermische Beschichtungsvorrichtung bereits vor dem Einführen in die Zylinderbohrung aktiviert werden, da ansonsten innerhalb der Zylinderbohrung eine unregelmässige Anfangsschicht entsteht. Beim Aktivieren der thermischen Beschichtungsvorrichtung ausserhalb der zu beschichtenden Zylinderbohrung besteht jedoch die Gefahr, dass bearbeitete Oberflächen -Passflächen- des Motorblocks durch den Beschichtungsstrahl in unerwünschter Weise "verschmutzt" werdenIn the manufacture of internal combustion engines find today increasingly engine blocks made of light metal use. However, since light metal in principle has no high abrasion and wear resistance, the cylinder bores or their walls are provided with a tread layer or it liners are inserted into the cylinder bores, which may also be provided with a tread layer. The application of such tread layers is usually carried out by means of thermal coating methods, in particular rotating Plasmatrons have proven to apply the layer. The problem with the application of such tread layers is u.a. in that the entire tread should be made homogeneous. Since a thermal coating apparatus such as a plasma spraying needs a certain start-up time until a homogeneous coating jet is generated, the thermal coating device must be activated prior to insertion into the cylinder bore, otherwise an irregular initial layer is formed within the cylinder bore. When activating the thermal coating device outside the cylinder bore to be coated, however, there is the danger that machined surfaces of the engine block are undesirably "contaminated" by the coating jet

Um diesem Problem zu begegnen und den Motorblock vor einem sogenannten "Overspray" zu schützen, sind flache Abdeckmasken bekannt, die auf die Oberseite des Motorblocks aufgelegt werden. Damit sind jedoch nicht alle Probleme gelöst, da durch die ausserhalb der zu beschichtenden Zylinderbohrung aktivierte Beschichtungsvorrichtung auch die Umgebung in Mitleidenschaft gezogen werden kann.To address this problem and to protect the engine block from a so-called "overspray", flat Abdeckmasken are known, which are placed on top of the engine block. However, this does not solve all the problems, since the surroundings can also be affected by the coating device activated outside the cylinder bore to be coated.

Aus der DE 199 10 665 ist eine Abdeckschablone bekannt, die zum Aufsetzen auf das Zylinderkurbelwellengehäuse einer Verbrennungskraftmaschine bestimmt ist. Diese Abdeckschablone weist mehrere Durchgangsöffnungen auf, über welche ein Beschichtungswerkzeug in den Innenraum des Zylinderkurbelwellengehäuses eingeführt werden kann. Die Abdeckschablone ist so ausgebildet, dass auch sämtliche weiterenFrom the DE 199 10 665 a cover template is known, which is intended to be placed on the cylinder crankshaft housing of an internal combustion engine. This cover template has a plurality of through openings, via which a coating tool can be introduced into the interior of the cylinder crankshaft housing. The cover template is designed so that all other

Bereiche des Zylinderkurbelwellengehäuses durch sie abgedeckt sind. Dazu besitzt die Abdeckschablone eine exakte plane Unterseite, die auf der bereits plan geschliffenen Zylinderkopffläche des Zylinderkurbelwellengehäuses aufzuliegen bestimmt ist. Es versteht sich, dass eine derartige Abdeckschablone teuer in der Herstellung ist. Ausserdem ist sie nicht universell einsetzbar, da sie an die Ausdehnung des Zylinderkurbelwellengehäuses angepasst werden muss, damit sämtliche weiteren Bereiche des Zylinderkurbelwellengehäuses abgedeckt sind. Zudem muss die Unterseite von Zeit zu Zeit nachbearbeitet werden, damit die Planheit erhalten bleibt. Dies ist insofern wichtig, da bei einer unebenen Unterseite die Gefahr besteht, dass beim Beschichten des Innenraums des Zylinderkurbelwellengehäuses über einen allfälligen Spalt zwischen der Zylinderkopffläche und der Abdeckschablone Beschichtungsmaterial auf die Zylinderkopffläche gelangen und diese verschmutzen kann.Areas of the cylinder crankshaft housing are covered by them. For this purpose, the cover template has an exact flat underside, which is intended to rest on the already flat ground cylinder head surface of the cylinder crankcase. It is understood that such a cover template is expensive to manufacture. In addition, it is not universally applicable, since it must be adapted to the extent of the cylinder crankshaft housing, so that all other areas of the cylinder crankshaft housing are covered. In addition, the underside must be reworked from time to time, so that the flatness is maintained. This is important inasmuch as with an uneven underside there is the risk that, when coating the interior of the cylinder crankshaft housing via a possible gap between the cylinder head surface and the covering template, coating material can get onto the cylinder head surface and contaminate it.

Aus dem Patent Abstract of Japan mit der Publikationsnummer 06065711 ist eine Maske bekannt, welche von der Unterseite eines Motorblocks her an das untere Ende der Zylinderlauffläche herangeführt wird. Die Maske ist zweiteilig ausgebildet, mit schrägen Trennflächen, damit die beiden Teile gegeneinander verschoben durch eine enge Stelle des Kurbelgehäuses hindurch in den Motorblock eingeführt werden können. Mit dieser Maske soll der Innenraum des Motorblocks, namentlich das Kurbelgehäuse, vor Verschmutzung beim thermischen Beschichten der Zylinderlaufflächen geschützt werden.From the Patent Abstract of Japan with publication number 06065711 a mask is known, which is brought from the bottom of an engine block ago to the lower end of the cylinder surface. The mask is formed in two parts, with oblique parting surfaces, so that the two parts against each other shifted through a narrow point of the crankcase can be inserted into the engine block. With this mask, the interior of the engine block, namely the crankcase, to be protected from contamination during thermal coating of the cylinder surfaces.

Die US 5 573 814 beschreibt eine aufblasbare Maske, mittels welcher eine Verschmutzung des Zylinderkurbelgehäuses durch eine Beschichtungsvorrichtung verhindert werden kann. Der aufblasbare Körper ist beispielsweise aus Fiberglas-Material gefertigt und teilweise mit Silikon beschichtet, wobei die geometrische Form der Maske in aufgeblasenem oder unaufgeblasenem Zustand variiert. Diese aufblasbare Maske kann mit einer flanschartigen Manschette kombiniert sein. Die aufblasbare Maske ist gemäss US 5 573 814 durch eine auf ihrer Oberfläche angebrachte Beschichtung wieder verwendbar.The US Pat. No. 5,573,814 describes an inflatable mask, by means of which contamination of the cylinder crankcase by a coating device can be prevented. For example, the inflatable body is made of fiberglass material and partially coated with silicone, with the geometric shape of the mask varying in an inflated or deflated condition. This inflatable mask can be combined with a flange cuff. The inflatable mask is according to US Pat. No. 5,573,814 reusable by a coating applied on its surface.

Die Aufgabe der Erfindung besteht nun darin, eine kostengünstige, mehrfach verwendbare und einfach anzuwendende Maske vorzuschlagen, welche ein Aktivieren der thermischen Beschichtungsvorrichtung ausserhalb der zu beschichtenden Zylinderbohrung ermöglicht, ohne dass der Motorblock oder die Umgebung durch Beschichtungspartikel verschmutzt wird, wobei die Maske nicht die gesamte Oberseite des Motorblocks abdecken soll und wobei eine hohe Qualität der aufgetragenen Schicht sichergestellt werden soll.The object of the invention is therefore to propose a cost-effective, reusable and easy-to-use mask, which allows activation of the thermal coating device outside the cylinder bore to be coated, without the engine block or the environment is contaminated by coating particles, the mask not the entire Cover the top of the engine block and where a high quality of the applied layer is to be ensured.

Diese Aufgabe wird durch eine Maske gelöst, welche die im Kennzeichen des Anspruchs 1 angeführten Merkmale aufweist.This object is achieved by a mask, which in the characterizing part of claim 1 having listed features.

Ausgehend von den aus dem Stand der Technik bekannten Masken wird im vorliegenden Fall ein anderer Ansatz gewählt. Dazu wird eine hohlzylindrisch ausgebildete und auf den Durchmesser der zu beschichtenden Zylinderbohrung abgestimmt Maske vorgeschlagen. Eine derartig ausgebildete Maske deckt nicht die gesamte Oberfläche des zu beschichtenden Motorblocks ab, sondern nur einen kreisringförmigen Bereich um die zu beschichtende Zylinderbohrung herum. Auf diesem kreisringförmigen Bereich um die zu beschichtende Zylinderbohrung herum liegt die Maske auf dem Motorblock auf. Eine derartige, hohlzylindrisch ausgebildete Maske hat u.a. den Vorteil, dass sie sehr einfach und günstig herzustellen ist und durch die kleine Auflagefläche eine sichere, spaltfreie Auflage der Maske auf dem Motorblock im Bereich der zu beschichtenden Zylinderbohrung erreicht werden kann.Starting from the masks known from the prior art, a different approach is chosen in the present case. For this purpose, a hollow cylindrical design and matched to the diameter of the cylinder bore to be coated mask is proposed. Such a trained mask does not cover the entire surface of the engine block to be coated, but only an annular area around the cylinder bore to be coated around. On this circular area around the cylinder bore to be coated, the mask rests on the engine block. Such a hollow cylindrical mask has u.a. the advantage that it is very simple and inexpensive to manufacture and can be achieved on the engine block in the region of the cylinder bore to be coated by the small contact surface safe, gap-free edition of the mask.

Bevorzugte Ausführungsformen der Maske sind in den abhängigen Ansprüchen 2 bis 9 umschrieben, während im Anspruch 10 eine Maskenanordnung mit zumindest zwei nach einem der Ansprüche 1 bis 9 ausgebildeten Masken beansprucht wird.Preferred embodiments of the mask are described in the dependent claims 2 to 9, while claimed in claim 10, a mask assembly having at least two masks formed according to one of claims 1 to 9.

Vorzugsweise ist die Höhe der Maske so gewählt, dass sie höher ist als die maximale vertikale Ausdehnung des Beschichtungsstrahls, wenn die Beschichtungsvorrichtung in die Maske eingeführt ist. Dadurch kann der Beschichtungskopf der Beschichtungsvorrichtung im nicht aktiven Zustand in die Maske eingeführt und darin aktiviert werden kann. Dadurch kann die Qualität des Beschichtungsvorgangs ganz allgemein sichergestellt werden, da keine nennenswerte Verschmutzung der Oberseite des Motorblocks durch den Beschichtungsstrahl entsteht, da keine Beschichtungspartikel aus der Maske austreten. Zum anderen wird eine regelmässige Beschichtung der Zylinderlauffläche erreicht, da der Beschichtungsvorgang ausserhalb der Zylinderbohrung gestartet wird und ein kontinuierlicher Schicht-Übergang von der Maske auf die Zylinderbohrung stattfinden kann.Preferably, the height of the mask is selected to be greater than the maximum vertical extent of the coating jet when the coating device is inserted into the mask. As a result, the coating head of the coating device can be introduced into the mask in the inactive state and activated therein. As a result, the quality of the coating process can be ensured in general since there is no appreciable contamination of the upper side of the engine block by the coating jet, since no coating particles emerge from the mask. On the other hand, a regular coating of the cylinder surface is achieved, since the coating process is started outside the cylinder bore and a continuous layer transition from the mask to the cylinder bore can take place.

In den Ansprüchen 11 bis 18 werden zudem Verfahren zum thermischen Beschichten von Zylinderbohrungen von Motorblöcken unter Verwendung von erfindungsgemäss gestalteten Masken beansprucht.Claims 11 to 18 also claim methods for thermally coating cylinder bores of engine blocks using masks designed according to the invention.

Die Erfindung wird anhand von Zeichnungen näher erläutert. Dabei zeigt: Fig. 1 einen Querschnitt durch einen Motorblock mit einem ersten Ausführungsbeispiel einer erfindungsgemässen Maske, und Fig. 2 einen Querschnitt durch den Motorblock mit einem zweiten Ausführungsbeispiel einer erfindungsgemässen Maske. Fig. 3 einen Querschnitt durch den Motorblock mit einem dritten Ausführungsbeispiel einer erfindungsgemässen Maske.The invention will be explained in more detail with reference to drawings. Showing: Fig. 1 a cross section through an engine block with a first embodiment of a mask according to the invention, and Fig. 2 a cross section through the engine block with a second embodiment of a mask according to the invention. Fig. 3 a cross section through the engine block with a third embodiment of a mask according to the invention.

Aus der Figur 1 ist schematisch ein im Querschnitt dargestellter Motorblock 1 eines Reihenmotors, eine auf dessen Oberseite 7 aufgesetzte Maske 4 sowie der Vorderteil 8 einer Beschichtungsvorrichtung ersichtlich. Als Beschichtungsvorrichtung kann beispielsweise ein Plasmaspritzgerät mit einem rotierenden Beschichtungskopf 9 vorgesehen werden. Der Motorblock 1 ist mit mehreren Zylinderbohrungen versehen, wobei aus dieser Darstellung nur eine Zylinderbohrung 2 ersichtlich ist. Die auf der Oberseite des Motorblocks 1 koaxial zur Zylinderbohrung 2 fixierte Maske 4 besteht aus einem rohrförmigen Aussenteil 5 und einem im wesentlichen hohlzylindrisch ausgebildeten Einsatz 6. Die Maske 4 sowie deren Einsatz 6 sind auf den Durchmesser der zu beschichtenden Zylinderbohrung 2 abgestimmt. Im vorliegenden Fall ist der Innendurchmesser des Einsatzes 6 geringfügig grösser als der Durchmesser der Zylinderbohrung 2. Da der Einsatz 6 mitbeschichtet wird verändert sich dessen Innendurchmesser mit zunehmender Einsatzdauer; d. h. der Innendurchmesser des Einsatzes 6 nimmt mit zunehmender Einsatzdauer ab. Im vorliegenden Fall ist dieser Einsatz 6 als Verschleissteil konzipiert, welches üblicherweise nach einer bis zehn Anwendungen entfernt wird. Durch das Vorsehen eines Einsatzes 6 braucht jeweils nicht die ganze Maske 4 ausgewechselt zu werden, sondern nur der Einsatz 6. Dieser ist vorzugsweise aus einem metallischen, keramischen oder organischen Material oder einer Kombination daraus hergestellt. Die Höhe der Maske 4 beträgt im Normalfall zwischen 20 und 40 mm. Sie ist auf jeden Fall so gewählt, dass der Beschichtungsstrahl 10, wie dargestellt, vollumfänglich auf der Innenseite der Maske 4 auftrifft, wenn der Beschichtungskopf 9 in die Maske 4 eingeführt ist. Indem der Beschichtungskopf 9 zuerst in die Maske 4 eingeführt und erst danach aktiviert wird, kann sichergestellt werden, dass keine nennenswerte Verschmutzung der Umgebung durch Beschichtungspartikel entsteht. Nachdem die Beschichtungsvorrichtung aktiviert ist, kann der Kopf 9 langsam in die Zylinderbohrung 2 eingefahren werden. Dadurch wird die Zylinderbohrung 2 bzw. deren Wände 3 kontinuierlich beschichtet und es entsteht keine unregelmässige Anfangsschicht.From the FIG. 1 is schematically a shown in cross-section engine block 1 of a series engine, a patch on its top 7 mask 4 and the front part 8 of a coating device can be seen. As a coating device, for example, a plasma spray gun with a rotating coating head 9 can be provided. The engine block 1 is provided with a plurality of cylinder bores, from which representation only one cylinder bore 2 can be seen. The mask 4 fixed coaxially to the cylinder bore 2 on the upper side of the engine block 1 consists of a tubular outer part 5 and a substantially hollow cylindrical insert 6. The mask 4 and its insert 6 are matched to the diameter of the cylinder bore 2 to be coated. In the present case, the inner diameter of the insert 6 is slightly larger than the diameter of the cylinder bore 2. Since the insert 6 is coated with the inner diameter changes with increasing duration of use; ie the inner diameter of the insert 6 decreases with increasing duration of use. In the present case, this insert 6 is designed as a wear part, which is usually removed after one to ten applications. By providing an insert 6, it is not necessary to replace the entire mask 4, but only the insert 6. This is preferably made from a metallic, ceramic or organic material or a combination thereof. The height of the mask 4 is normally between 20 and 40 mm. It is in any case chosen so that the coating jet 10, as shown, fully impinges on the inside of the mask 4 when the coating head 9 is inserted into the mask 4. By first introducing the coating head 9 into the mask 4 and only then activating it, it is possible to ensure that no appreciable contamination of the surroundings by coating particles is produced. After the coating device is activated, the head 9 can be slowly retracted into the cylinder bore 2. As a result, the cylinder bore 2 or its walls 3 is coated continuously and there is no irregular initial layer.

Der Einsatz 6 ist vorzugsweise lose in den Aussenteil 5 eingesetzt, so dass er in vertikaler Richtung relativ zum Aussenteil 5 bewegbar ist. Um ein Herausfallen des Einsatzes 6 aus dem Aussenteil 5 zu verhindern, beispielsweise wenn letztere vom Motorblock 1 abgehoben wird, ist der Einsatz 6 mit einem Anschlag in Form einer auf der Oberseite umlaufenden Schulter 6a versehen. Der Einsatz 6 ist vorzugsweise etwas höher als der Aussenteil 5 ausgebildet, so dass er mit der Stirnseite auf dem Motorblock 1 aufliegt -und nicht mit der Schulter 6a auf dem Aussenteil 5 der Maske- wenn die Maske 6 auf den Motorblock 1 aufgesetzt ist. Dadurch wird zum einen eine spaltfreie Auflage des Einsatzes 6 auf dem Motorblock 1 sichergestellt und zum anderen kann der Einsatz 6 auf einfachste Weise ausgetauscht werden. Durch das Vorsehen unterschiedlicher Einsätze kann die Maske zudem sehr schnell an unterschiedliche Bohrungsdurchmesser angepasst werden.The insert 6 is preferably inserted loosely in the outer part 5, so that it is movable relative to the outer part 5 in the vertical direction. In order to prevent falling out of the insert 6 from the outer part 5, for example, when the latter is lifted from the engine block 1, the insert 6 is provided with a stop in the form of a circumferential shoulder 6a on the top. The insert 6 is preferably formed slightly higher than the outer part 5, so that it rests with the end face on the engine block 1 - and not with the Shoulder 6a on the outer part 5 of the mask - when the mask 6 is placed on the engine block 1. This ensures, on the one hand, a gap-free support of the insert 6 on the engine block 1 and, on the other hand, the insert 6 can be replaced in the simplest manner. By providing different inserts, the mask can also be adapted very quickly to different bore diameters.

Die Maske 4 kann mit Positioniermitteln zum Ausrichten und/oder Fixieren gegenüber dem Motorblock 1 versehen werden. Dazu können beispielsweise Stifte oder Bolzen vorgesehen werden, welche in im Motorblock 1 eingelassene Bohrungen eingreifen. Sowohl die Positioniermittel wie auch die in den Motorblock 1 eingelassene Bohrungen sind im vorliegenden Fall jedoch nicht dargestellt.The mask 4 can be provided with positioning means for aligning and / or fixing with respect to the engine block 1. For this example, pins or bolts may be provided, which engage in sunken in the engine block 1 holes. Both the positioning means as well as the recessed into the engine block 1 holes are not shown in the present case.

Das Aufbringen der Schicht erfolgt vorzugsweise durch Plasmaspritzen, Hochgeschwindigkeitsflammspritzen, Lichtbogenspritzen, Flammspritzen, Inertgasplasmaspritzen oder Inertgaslichtbogenspritzen.The coating is preferably applied by plasma spraying, high-speed flame spraying, arc spraying, flame spraying, inert gas plasma spraying or inert gas arc spraying.

Fig. 2 zeigt einen Querschnitt durch den Motorblock mit einem zweiten Ausführungsbeispiel einer Maske 4a. Diese ist wiederum rohrförmig, d. h. hohlzylindrisch ausgebildet, wobei kein Einsatz vorgesehen ist. Die Maske 4a ist derart konzipiert, dass die auf der Innenseite durch die Beschichtungsvorrichtung aufgetragenen Schichten 11, 12 bei Bedarf mechanisch entfernt werden können, beispielsweise durch ausdrehen. Das Entfernen der Schicht kann auch durch Strahlen mit abrasiven Pulvern wie beispielsweise Korund (Al2O3) oder Siliziumcarbid (SiC) erfolgen. Fig. 2 shows a cross section through the engine block with a second embodiment of a mask 4a. This is in turn tubular, ie hollow cylindrical, with no use is provided. The mask 4a is designed in such a way that the layers 11, 12 applied on the inside by the coating device can be mechanically removed if necessary, for example by unscrewing. The removal of the layer can also be done by blasting with abrasive powders such as corundum (Al2O3) or silicon carbide (SiC).

Der Innendurchmesser der Maske 4a ist vorzugsweise etwas grösser als der Durchmesser der Zylinderbohrung 2, so dass die Schichten 11, 12 nicht komplett, d. h. bis auf den Innendurchmesser der Maske 4a entfernt werden müssen, was ohne Beschädigung bzw. Schwächung der Maske 4a ohnehin kaum möglich wäre. Auf das vorliegende Beispiel bezogen würde es genügen, wenn die innere Schicht 11 entfernt würde.The inner diameter of the mask 4a is preferably slightly larger than the diameter of the cylinder bore 2, so that the layers 11, 12 are not complete, d. H. must be removed to the inner diameter of the mask 4a, which would hardly be possible anyway without damage or weakening of the mask 4a. With reference to the present example, it would be sufficient if the inner layer 11 were removed.

Fig. 3 zeigt ein weiteres Ausfühnjngsbeispiel der Erfindung. In diesem Fall ist eine Maskenanordnung vorgesehen, die aus mehreren Masken besteht, welche durch einen Rahmen 13 miteinander verbunden sind. Der Abstand zwischen den einzelnen Masken ist dem Abstand zwischen Zylinderbohrungen des Motorblocks angepasst. Auch in diesem Fall liegt die einzelne Maske 4 bzw. deren Einsatz 6 im wesentlichen nur auf einer kreisringförmigen Fläche entlang der zu beschichtenden Zylinderbohrung 2 auf. Fig. 3 shows a further Ausfühnjngs example of the invention. In this case, a mask arrangement is provided, which consists of a plurality of masks, which are interconnected by a frame 13. The distance between the individual masks is adapted to the distance between cylinder bores of the engine block. In this case too, the individual mask 4 or its insert 6 lies substantially only on an annular surface along the cylinder bore 2 to be coated.

Vorzugsweise wird während des Beschichtungsvorgangs Luft durch die sich im aktiven Beschichtungsvorgang befindliche Zylinderbohrung geleitet, indem die Luft auf der Unterseite der Zylinderbohrung über nicht näher dargestellte Mittel abgesaugt wird. Ein Absaugen der Luft hat den Vorteil, dass die nicht auf die Wandung der Zylinderbohrung aufgetragenen Beschichtungspartikel zuverlässig nach unten abgeführt werden und sich nicht auf der Oberseite des Motorblocks niederschlagen können. Ausserdem kann durch eine gezielte Luftströmung der Gehalt von in der Schicht gebundenem Sauerstoff (Oxydanteil) definiert beeinflusst werden. Zum gezielten Beeinflussen der Schichteigenschaften kann es sich auch anbieten, anstelle von Luft beispielsweise Stickstoff oder ein anderes gasförmiges Medium durch die sich im aktiven Beschichtungsvorgang befindliche Zylinderbohrung zu leiten. Das Vorsehen einer erfindungsgemäss ausgebildeten Maske 4, 4a bringt diesbezüglich einen Vorteil mit sich, indem durch die als Verlängerung der Zylinderbohrung 2 wirkende Maske innerhalb der Zylinderbohrung 2 günstigere Strömungsbedingungen vorherrschen als ohne Maske, was sich letztlich wiederum in einer gleichmässigeren Qualität der aufgetragenen Schicht äussert.Preferably, air is passed through the cylinder bore located in the active coating process during the coating process by the air is sucked off on the underside of the cylinder bore via means not shown. Extraction of the air has the advantage that the coating particles not applied to the wall of the cylinder bore can be reliably removed downwards and can not be deposited on the upper side of the engine block . In addition, the content of oxygen bound in the layer (oxide content) can be influenced in a defined manner by means of a targeted air flow. For selectively influencing the layer properties, it may also be appropriate, for example, to direct nitrogen instead of air, or another gaseous medium, through the cylinder bore located in the active coating process. The provision of an inventively designed mask 4, 4a brings with it an advantage in that prevail by acting as an extension of the cylinder bore 2 mask within the cylinder bore 2 more favorable flow conditions than without mask, which in turn manifests itself in a more uniform quality of the applied layer.

Es versteht sich, dass die beiden gezeigten Ausführungsbeispiele nicht als abschliessend zu betrachten sind. Beispielsweise können auch Maskenanordnungen im Sinne einer Mehrfachmaske vorgesehen werden, da häufig zwei Beschichtungsvorrichtungen gleichzeitig im Einsatz stehen. Der Abstand zwischen den Masken wird dabei dem Abstand zwischen den Zylinderbohrungen des Motorblocks angepasst, wobei im allgemeinen nicht direkt nebeneinander liegende Zylinderbohrungen gleichzeitig beschichtet werden, sondern bei einem vierzylindrigen Reihenmotor beispielsweise zuerst die Bohrungen 1 und 3 und danach die Bohrungen 2 und 4.It is understood that the two embodiments shown are not to be considered as exhaustive. For example, it is also possible to provide mask arrangements in the sense of a multiple mask, since often two coating devices are used simultaneously. The distance between the masks is adjusted to the distance between the cylinder bores of the engine block, which are not directly adjacent cylinder bores are coated simultaneously, but in a four-cylinder in-line engine, for example, first the holes 1 and 3 and then the holes 2 and 4.

Claims (18)

  1. A protective masking device (4, 4a) adapted to rest on an engine block (1) having cylinder bores during a thermal coating operation of said cylinder bores (2), whereby the protective masking device (4, 4a) has a hollow cylindrical shape with an inner diameter selected in relation to the diameter of the cylinder bore (2) to be coated, characterized in that the protective masking device (4, 4a) comprises a tube shaped outer portion (5) and an insert member (6) inserted into said outer portion, in which said protective masking device is adapted to rest only along an annular area along the cylinder bore (2) to be coated.
  2. A protective masking device (4) according to claim 1, characterized in that the insert member (6) projects over said outer portion (5) at the bottom side thereof.
  3. A protective masking device (4) according to claim 1 or 2, characterized in that said insert member (6) is loosely inserted in said outer portion (5) to be vertically movable with regard to said outer portion (5), said insert member (6) being provided with a stop member (6a) adapted to prevent said insert member (6) from falling out of said outer portion (5).
  4. A protective masking device (4) according to any one of claims 1 to 3, characterized in that the insert member (6) comprises a circumferential shoulder (6a) located at the top of said insert member.
  5. A protective masking device (4) according to any one of the preceding claims, characterized in that said protective masking device has a height which is selected such that it is greater than the maximal vertical extension of a coating jet (10) when a coating head (9) is moved into the interior of said protective masking device (4).
  6. A protective masking device (4) according to any one of the preceding claims, characterized in that said insert member (6) is made of a metallic, ceramic or organic material or of a combination of said materials.
  7. A protective masking device (4a) according to claim 1, characterized in that the protective masking device is designed such that at least a portion of a layer or of several layers (11, 12) applied to the inner side of the protective masking device (4a) during the coating operation of the related cylinder bore (2) is mechanically removable.
  8. A protective masking device (4, 4a) according to any one of the preceding claims, characterized in that said protective masking device (4, 4a) has a height of between 10 and 60 millimeters.
  9. A protective masking device (4, 4a) according to any of the preceding claims, characterized in that said protective masking device comprises positioning means for positioning and/or fixing it with regard to the engine block (1).
  10. A protective masking device assembly comprising at least two protective masking devices according to any of claims 1 to 9, whereby the distance between the protective masking devices is adapted to the distance between the cylinder bores of the engine block.
  11. A method of thermally coating cylinder bores (2) of engine blocks (1) making use of a protective masking device (4, 4a) according to claim 1, characterized in that a coating head (9) of said thermal coating apparatus (8) is moved into the interior of the protective masking device (4, 4a) such that the coating jet entirely hits the inner walls of said masking device immediately after its activation.
  12. A method of thermally coating cylinder bores (2) of engine blocks (1) making use of a protective masking device (4, 4a) according to claim 1, characterized in that the insert member (6) is replaced by a new one after one to ten coating operations.
  13. A method of thermally coating cylinder bores (2) of engine blocks (1) making use of a protective masking device (4a) according to claim 2, characterized in that the layer or layers (11, 12) applied to the inner wall of said protective masking device (4a) is at least partially mechanically removed after one to ten coating operations.
  14. A method according to claim 13, characterized in that the layer or said layers applied to the inner wall of said protective masking device (4a) are removed by blasting with an abrasive powder, particularly corundum (Al2O3) or silicon carbide (SiC).
  15. A method according to any one of claims 11 to 14, characterized in that a thermal coating apparatus (8) having a rotating coating head (9) is used.
  16. A method according to any one of claims 11 to 15, characterized in that a flow of air is led through the cylinder bore (2) that is subjected to the active coating operation.
  17. A method according to any one of claims 11 to 16, characterized in that a flow of nitrogen or another gaseous medium is led through the cylinder bore (2) that is subjected to the active coating operation.
  18. A method according to any one of claims 11 to 17, characterized in that the application of the layer (11, 12) is performed by plasma spraying, high speed flame spraying, arc spraying, flame spraying, inert gas plasma spraying or inert gas arc spraying.
EP02405024A 2001-05-15 2002-01-16 Mask member for placing on an engine body during the thermal coating of the internal cylinder bores and process using this masking member Expired - Lifetime EP1258540B1 (en)

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DE19929247A1 (en) * 1998-12-18 2000-06-21 Volkswagen Ag Thermal coating of cavity surfaces, especially plasma spray coating of cylinder running surfaces of an i. c. engine crank-case, comprises directing an inert gas stream parallel to the surfaces being coated
US6395090B1 (en) * 1999-08-16 2002-05-28 Ford Global Technologies, Inc. Masking for engine blocks for thermally sprayed coatings

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CA2373001A1 (en) 2002-11-15
DE20200739U1 (en) 2002-03-28
JP2002339053A (en) 2002-11-27
KR100867241B1 (en) 2008-11-10
KR20020087342A (en) 2002-11-22
CA2373001C (en) 2010-05-11
US20020172769A1 (en) 2002-11-21
ATE548478T1 (en) 2012-03-15
JP4230703B2 (en) 2009-02-25
EP1258540A1 (en) 2002-11-20

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