Research progress of surface technology in piston assembly-cylinder liner system of internal combustion engines
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摘要: 通过分析与总结国内外内燃机活塞组件-缸套系统表面技术研究现状和发展趋势,梳理了表面织构和表面涂层技术在内燃机关键运动副减摩抗磨与节能应用中的特点; 剖析了表面织构加工技术、表面织构形貌特征与分布、表面涂层制备工艺、表面耐磨涂层、表面热障涂层和表面技术与润滑的协同效应对运动副摩擦性能的影响。分析结果表明:激光表面织构(LST)能有效改善运动副表面的摩擦学性能,直接/间接激光冲击表面织构(LSSP)技术已成为高效、灵活的表面织构加工方法,但由于织构加工工艺、形貌和分布特征对摩擦学性能的影响较为复杂,仍需进一步结合内燃机活塞组件-缸套系统的工况特性研究并优化表面织构的形貌和分布特征; 大气等离子喷涂(APS)和超音速火焰(HVOF)喷涂制备的耐磨涂层和热障涂层(TBC)具有良好的耐磨、隔热和抗氧化性,可使内燃机活塞组件-缸套系统表面金属基复合材料、类金刚石(DLC)材料、纳米复合材料和陶瓷材料涂层的减摩抗磨和节能成效明显,但涂层材料种类繁多,很难形成统一的行业标准、规范以及工业化应用; 内燃机活塞组件-缸套系统的动力学特性和表面织构、表面涂层与润滑的协同作用复杂,将来仍需综合考虑多场条件下各种表面技术耦合的减摩抗磨机理,进一步完善内燃机活塞组件-缸套系统表面复合理论和技术体系,为内燃机产业的绿色和高效发展提供技术指导。Abstract: Through the analysis and summary of global research statuses and development trends of surface technology in piston assembly-cylinder liner systems of internal combustion engines, the characteristics of surface textures and surface coating technologies in the applications of friction reduction, wear resistance, and energy saving of internal combustion engine key motion pairs were examined. The influences of surface texture processing technology, morphological and distribution characteristics, surface coating preparation technology, surface wear resistant coating, surface thermal barrier coating, and the synergistic effect of surface technology and lubrication on the tribological properties of motion pairs were analyzed in detail. Analysis results show that the laser surface texture (LST) can effectively improve the surface tribological properties of motion pairs. The direct/indirect laser shock surface patterning (LSSP) technology is an efficient and flexible processing method for the surface texture processing. Because the effects of texture processing technology, morphology, and distribution characteristics on the tribological properties are complex, further study and optimization on the morphology and distribution characteristics of surface texture are still necessary based on the operating conditions of piston assembly-cylinder liner systems of internal combustion engines. The wear resistant coatings and thermal barrier coatings (TBC) prepared by the atmospheric plasma spraying (APS) and high velocity oxy-fuel (HVOF) spray, have good wear resistance, heat insulation, and oxidation resistance. The metal matrix composites, diamond-like carbon (DLC) materials, nanocomposites, and ceramic materials on the surface of piston assembly-cylinder liner systems of internal combustion engines exhibit obvious effects in reducing friction, wear resistance and energy-saving. However, because of the wide variety of coating materials, developing a unified industrial standard and norms as well as industrial applications are difficult. The dynamics characteristics, synergistic effect of surface texture, surface coating, and lubrication are complex in the piston assembly-cylinder liner systems of internal combustion engines. In the future, thorough considerations of friction reduction and wear resistance mechanisms of various surface technologies coupling under multi-field conditions and further improvement of surface composite theory and technology system for piston assembly-cylinder liner systems are necessary, to provide a technical guidance for the green and efficient development of internal combustion engines. 3 tabs, 14 figs, 111 refs.
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表 1 汽油机和柴油机活塞组件材料和表面技术比较
Table 1. Comparison of piston assembly materials and surface technologies between gasoline engine and diesel engine
内燃机类型 汽油机 柴油机 活塞材料 铝硅合金 铝硅合金、铸铁 活塞环材料 钢(合金)、灰铸铁(合金和调质) 球墨铸铁(合金和调质)、18%铬钢 表面织构技术与形状 珩磨、激光表面织构(Laser Surface Texture, LST)、光刻、电铸和注塑(Lithographie Galvanoformung Abformung, LIGA)、电解加工,微小凹坑、微小沟槽、仿生几何形貌 珩磨、LST、LIGA、电解加工、微小凹坑、微小沟槽、仿生几何形貌 表面涂层技术与材料 电镀、大气等离子喷涂(Air Plasma Spraying, APS)、超音速火焰(High Velocity Oxy-Fuel, HVOF)喷涂、石墨、TinO2n-1、类金刚石(Diamond-Like Carbon, DLC)、SiC-Al2O3、Mo-(NiCr-Cr3C2) 电镀、APS、HVOF、DLC、氧化锆、MoN、WC/CrC、Cr3C2/NiCr 表 2 激光表面织构技术比较
Table 2. Comparison of LST technologies
评估标准 激光烧蚀 激光干涉 激光冲击加工 直接/间接激光冲击加工 灵活性 ★★★★ ★★★★ ★★★ ★★★★ 效率 ★★★ ★★★★★ ★★★ ★★★★ 织构特征分辨极限 1 μm钛合金 0.1 μm硅基材料 10 μm铝合金 2 μm镁铝合金 表面硬化机理 热致相变(只对某些特定金属) 热致相变(只对某些特定金属) 表面塑性变形(对所有金属材料) 表面塑性变形 适用材料 金属、聚合物、陶瓷和复合材料 金属、聚合物、陶瓷和复合材料 金属材料 大多数金属材料 缺点 精度和灵活性受限 材料退化、相变、残余热应力、表面氧化 低效率、低扩展性 高应力 成本 ★★★★ ★★★ ★★★ ★★★★ 表 3 APS和HVOF热喷涂技术性能比较
Table 3. Property comparison of thermal spraying technologies using APS and HVOF
喷涂方法 APS HVOF 火焰温度/℃ 10 000~30 000 2 500~3 100 粒子速度/(m·s-1) 200~500 400~800 结合强度/(N·mm-2) 30~70 70~110 孔隙率/% < 5 < 1 喷涂效率/(kg·h-1) 2~10 1~5 适用材料 各种陶瓷,高熔点、耐磨、耐热材料 金属及其合金粉末,易氧化、失碳和降解的纳米硬质耐磨涂层 涂层优点 控制方便、准确,氧化物和杂质含量少; 对基体适应能力强; 厚度、硬度和防腐效果等方面比传统方法效果好,有较强的环境适应能力 表面光滑,喷涂速度快,沉积率高; 氧化物含量低,化学成分和相组成稳定 缺点 对工作气体的纯度要求高; 小孔径内表面喷涂困难; 喷涂时劳动保护要求高,喷涂过程会产生巨大噪声、强光辐射、有害气体(臭氧、氮氧化物等)、金属蒸汽粉尘等 排放物对环境有害,功能扩展性受限 成本 设备投资大,成本高 燃料消耗大,成本较高 -
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