Daimler Chrysler Ag

Mercedes-benz Aktiengesellschaft

Daimler Ag

Peter Stocker

Tilmann Haug

Franz Rueckert

Helmut Schaefer

Franz Ruckert

Franz R&uuml;ckert

Roland Biedermann

Roland Rieger

Patrick Izquierdo

Tilman Haug

Harald Pfeffinger

Klaus Land

Oliver Storz

Axel Heuberger

Herbert Gasthuber

Micheal Voit

Helmut Proefrock

Hartmut Engels

Dezsoe Schilling

Wolfgang Reichle

Peter Lingl

A cylinder liner () for a cylinder block has a contouring () at one end. The contouring () serves to support the liner () on a sleeve () inside a die-casting tool. When the liner () is cast in, recesses () of the liner () are filled by the material of the cylinder crankcase whereby preventing the liner () from seating toward an oil chamber (). The invention also relates to a method for producing a cylinder liner of the aforementioned type.

Cylinder liner for a cylinder crankcase

A casting die for the production of a cylinder block/crankcase of an internal combustion engine includes at least one sleeve, which may be moved relative to its axis and is fitted in each case with a cylinder liner, the sleeve keeping open the cylinder bore of the cylinder block/crankcase and extending from a wall on the cylinder-head side of the die to a wall on the crankshaft side of the casting die. The cylinder liner ends at least 3 mm before the wall on the cylinder-head side of the casting die, and the cylinder liner is held at a distance from the wall on the cylinder-head side of the casting die by a spacer.

Casting die for the production of a cylinder block/crankcase

In a process for casting a metallic semi-finished product into a casting, the semi-finished product is roughened on a surface which faces the casting, then being placed in a defined position in a casting mold and surrounded with casting metal, after which a firm bond is formed between the semi-finished product and the solidified casting metal at the roughened surface. The surface of the semi-finished product is roughened by high-pressure water blasting.

Process for incorporating a metallic semi-finished product by casting

In a cylinder liner of an internal combustion engine for casting into a light-metal crankcase to be cast, in order, during the casting in of the cylinder liner, to achieve as good a binding as possible of the cylinder liner to the surrounding casting material, the cylinder liner has on the outer circumference, in the region of the upper dead center of the piston rings of a piston guided in the liner, an activation layer which consists of a material which, due to the heat effect of the liquid casting material, connects metallically more rapidly to the latter than the liner material, and in that the cylinder liner has a rough surface on the outer circumference following the region of the upper dead center.

Cylinder liner of an internal combustion engine

The invention relates to a cylinder liner made from a hypereutectic aluminum/silicon alloy which is surrounded by a surround casting material, which is characterized in that the minimum ratio of the wall thickness of the surround casting material of the cylinder liner is 1.4.

Cylinder liner

A cylinder liner cast into a reciprocating piston engine made of a supereutectic aluminum/silicon alloy which is free of mixed-in particles of hard material and which is composed in such a way that fine silicon primary crystals and intermetallic particles automatically form from the melt as hard particles. A blank is allowed to grow from finely sprayed melt droplets by spray compaction, with a fine distribution of hard particles being produced by setting the spray for small melt droplets. The fine-grained, hard particles formed from the melt and also the mechanical exposure of the hard particles on the surface of the cylinder results not only in high wear resistance and high contact area of the surface, but also in gentle treatment of the piston and its rings.

Cylinder liner comprising a supereutectic aluminum/silicon alloy for sealing into a crankcase of a reciprocating piston engine

Surface activation is intended to ensure that a cylinder liner can be anchored in the casting material of a light-metal crankcase with greater bonding. For surface activation, the surface of the cylinder liner is roughened mechanically. Advantageously, copper particles are also implanted into the treated surface. It is necessary to ensure that the time span between surface activation and casting-in is short. Moreover, the activated surface, as far as possible, should not be touched by hand.

Method for producing a cylinder liner blank to be cast into a light-alloy crankcase of a reciprocating engine

A cylinder-liner blank which preferably consists of a hypereutectic aluminum/silicon alloy and is cast into a crankcase. A special surface treatment achieves better material bonding of the liner in the crankcase. The blank has a roughness of 30 to 60 &mgr;m on its outside, in the form of pyramid-like or lancet-like protruding material scabs or material accumulations. To obtain this roughness, the surface is blasted with particles which are broken so as to have sharp edges and consist of a brittle hard material, preferably high-grade corundum, with an average grain size of about 70 &mgr;m. A fine fraction is formed and is continuously separated off. The average grain size is maintained by adding new particles.

Two part light metal coating and method of making same

A tribological coating made of a copper-free highly hypereutectic aluminum/silicon alloy and/or of a copper-free aluminum/silicon composite material composed such that fine silicon primary crystals and/or silicon particles, intermetallic phases, and oxides form as hard particles during the production of the layers in the atmospheric thermal spraying method and/or are anchored in the structure. The surface of the coating can be machined economically by short-chipping using conventional tools, so that additional alloy elements such as copper for forming additional intermetallic phases such as Al,Cu can be eliminated. This is significant because conventional AlSi cylinder liners in reciprocating engines pose problems in conjunction with certain fuels because of their copper content.

Coating consisting of hypereutectic aluminum/silicon alloy and/or an aluminum/silicon composite material

A cylinder liner cast into a reciprocating piston engine made of a supereutectic aluminum/silicon alloy which is free of mixed-in particles of hard material and which is composed in such a way that fine silicon primary crystals and intermetallic particles automatically form from the melt as hard particles. A blank is allowed to grow from finely sprayed melt droplets by spray compaction, with a fine distribution of hard particles being produced by setting the spray for small melt droplets. The blank can then be formed by cold extrusion to create a shape approximating the cylinder lining. After premachining, the surface is fine machined, honed in at least one stage and then the hard particles lying at the surface are mechanically or chemically exposed, forming plateau areas of hard particles which project above the remaining surface of the base microstructure of the alloy. The mechanical exposure of the primary crystals or particles is carried out by a honing process using felt strips which are cylindrically shaped on the outside and a slurry of SiC particles in honing oil. The chemical exposure of the primary crystals or particles is carried out by using aqueous alkali. The fine-grained, hard particles formed from the melt and also the mechanical exposure of the hard particles on the surface of the cylinder results not only in high wear resistance and high contact area of the surface, but also in gentle treatment of the piston and its rings.

Cylinder liner of a hypereutectic aluminum/silicon alloy for use in a

A coating for a cylinder bore of a reciprocating engine with an iron, aluminum, or magnesium base comprises a hypereutectic aluminum/silicon alloy. The alloy is applied to a cylinder wall by thermal spraying.

Coating for a cylinder of a reciprocating engine

A cylinder-liner blank which preferably consists of a hypereutectic aluminum/silicon alloy and is cast into a crankcase. A special surface treatment achieves better material bonding of the liner in the crankcase. The blank has a roughness of 30 to 60 .mu.m on its outside, in the form of pyramid-like or lancet-like protruding material scabs or material accumulations. To obtain this roughness, the surface is blasted with particles which are broken so as to have sharp edges and consist of a brittle hard material, preferably high-grade corundum, with an average grain size of about 70 .mu.m. A fine fraction is formed and is continuously separated off. The average grain size is maintained by adding new particles.

Light metal part activation for casting with another light metal part

The invention relates to a cylinder liner sealed into a reciprocating piston engine comprising a supereutectic aluminum/silicon alloy which is free of mixed-in particles of hard material and which is composed in such a way that fine silicon primary crystals and intermetallic particles automatically form from the melt as hard particles. A blank is allowed to grow from finely sprayed melt droplets by spray compaction, with a fine distribution of hard particles being produced by setting the spray for small melt droplets. The blank can then be formed by cold extrusion to create a shape approximating the cylinder lining. After premachining, the surface is fine machined, honed in at least one stage and then the hard particles lying at the surface are mechanically exposed, is forming plateau areas of hard particles which project above the remaining surface of the base microstructure of the alloy. The mechanical exposure of the primary crystals or particles is carried out by a honing process using felt strips which are cylindrically shaped on the outside and a slurry of SiC particles in honing oil. The fine-grained, hard particles formed from the melt and also the mechanical exposure of the hard particles on the surface of the cylinder results not only in high wear resistance and high contact area of the surface, but also in gentle treatment of the piston and its rings.

Cylinder liner comprising a supereutectic aluminum/silicon alloy for

The invention relates to a cylinder liner, cast into a reciprocating piston engine, of a highly hypereutectic aluminum/silicon alloy which is free of hard material particles independent of the melt and has such a composition that fine primary silicon crystals and intermetallic phases automatically form from the melt as hard particles. By spray-compacting, a blank of finely sprayed melt droplets is caused to grow, a fine distribution of the hard particles being produced by controlled introduction of small melt droplets. The blank can be transformed by an extrusion step into a form approximating the cylinder liner. After subsequent premachining with chip removal, the running surface is precision-machined and subsequently honed in at least one stage, after which the hard particles located in the running surface are exposed, plateau faces of the particles being formed, which faces protrude from the remaining surface of the matrix structure of the alloy. The exposing of the primary crystals and/or particles is effected chemically, using aqueous alkali. Owing to the fine-grained hard particles formed in the melt and to their large proportion in the matrix structure and owing to the exposing of the hard particles in the matrix structure, not only high wear resistance and a high load bearing proportion of the running surface result, but also the possibility of using inexpensive piston ring fittings and piston coatings with, at the same time, low oil consumption and correspondingly low hydrocarbon emissions.

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Sulzbach, Germany

Peter Stocker