LAYER SINTERED VALVE SEAT RING, PROCESS FOR ITS PRODUCTION, COMBINATIONS THEREWITH AND THEIR USE

Abstract

A layer-sintered valve seat ring is disclosed. The layer-sintered valve seat ring includes at least two materials including a function material for a tribological contact with an opposite runner and a support material for the function material. The support material includes: C: 0.5 to 1.8% by weight; Cr: 3 to 16% by weight; Mo: 1 to 5% by weight; W: 0.5 to 5.5% by weight; V: 0.4 to 4.0% by weight; Cu: 12 to 25% by weight; Fe: 41.3 to 82.6% by weight; Mn: up to 0.6% by weight; Si: up to 1.8% by weight; and a remainder of production-related contamination in the form of at least one of Ni, Co, Ca, P, and S that are present in contents of <0.3% by weight each.

Claims

1. A layer-sintered valve seat ring, comprising: at least two materials, wherein one material is a function material for a tribological contact with an opposite runner and another material is a support material for the function material, wherein the support material includes: C: 0.5 to 1.8 % by weight; Cr: 3 to 16 % by weight; Mo: 1 to 5 % by weight; W: 0.5 to 5.5 % by weight; V: 0.4 to 4.0 % by weight; Cu: 12 to 25 % by weight; Fe: 41.3 to 82.6 % by weight; Mn: up to 0.6 % by weight; Si: up to 1.8 % by weight; wherein a remainder of the support material is production-related contaminations in the form of at least one of Ni, Co, Ca, P and S that are present in contents of <0.3 % by weight each.

2. The layer-sintered valve seat ring according to claim 1, wherein the support material contains: C: 1.0 to 1.8% by weight; Cr: 10 to 15% by weight; Mo: 2.5 to 5% by weight; W: 0.8 to 1.5% by weight; Si: 0.2 to 1.8% by weight; V: 0.4 to 1.5% by weight; Cu: 12 to 25% by weight; Fe: 47.8 to 73.1% by weight; Mn: up to 0.6% by weight; and wherein the remainder are production-related contaminations in the form of at least one of Ni, Co, Ca, P and S that are present in contents of <0.3% by weight each.

3. The layer-sintered valve seat ring according to claim 1, wherein the support material contains: C: 0.7 to 1.1% by weight; Cr: 3 to 5% by weight; Mo: 3 to 5% by weight; W: 3.5 to 5.5% by weight; V: 1.0 to 2.0% by weight; Cu: 15 to 25% by weight; Fe: 54.8 to 73.8% by weight; Mn: up to 0.6% by weight; Si: up to 1.0% by weight; wherein the remainder are production-related contaminations in the form of at least one of Ni, Co, Ca, P and S, which are present in contents of <0.3% by weight each where applicable.

4. The layer-sintered valve seat ring according to claim 1, wherein the support material contains: C: 1.0 to 1.8% by weight; Cr: 12 to 16% by weight; Mo: 1 to 2.5% by weight; W: 0.8 to 2.0% by weight; Si: 0.2 to 1.2% by weight; V: 0.4 to 1.5% by weight; Cu: 12 to 25% by weight; Fe: 49.4 to 72.6% by weight; Mn: up to 0.6% by weight; wherein the remainder are production-related contaminations in the form of at least one of Ni, Co, Ca, P and S that are present in contents of <0.3% by weight each.

5. The layer-sintered valve seat ring according to claim 1, wherein the function material includes: C: 0.7 to 1.5% by weight; Cr: 2 to 4% by weight; Mo: 12 to 18% by weight; W: 2 to 4% by weight; V: 1 to 2% by weight; Cu: 10 to 20% by weight; Co: 6 to 14% by weight; Fe: 34.5 to 66.3% by weight; Mn: up to 1.0% by weight; Si: up to 1% by weight; wherein a reminder of the function material is production-related contaminations in the form of at least one of Ni, Co, Ca, P and S that are present in contents of <0.3% by weight each.

6. A combination of the layer-sintered valve seat ring according to claim 1 and a valve, wherein the valve is hard-faced or nitrided.

7. A combination of the layer-sintered valve seat ring according to claim 1 and a valve, wherein the valve is composed of a nickel-based alloy or an iron-based alloy with an Ni content of 10 to 40% by weight.

8. A combination of the layer-sintered valve seat ring according to claim 1 and a cylinder head of a cast iron alloy, wherein the cast iron alloy contains lamellar graphite, vermicular graphite or spheroidal graphite, and wherein the layer-sintered valve seat ring is inserted into the cylinder head with a press fit.

9. A method for producing a layer-sintered valve seat ring , comprising the steps: producing starting material powders for a support material and a function material ,the support material including: C: 0.5 to 1.8% by weight; Cr: 3 to 16% by weight; Mo: 1 to 5% by weight; W: 0.5 to 5.5% by weight, V: 0.4 to 4.0% by weight; Cu: 12 to 25% by weight; Fe: 41.3 to 82.6% by weight; Mn: up to 0.6% by weight, Si: up to 1.8% by weight; a remainder of production-related contamination in the form of at least one of Ni, Co, Ca, P, and S that are present in contents of <0.3% by weight each; uniaxial pressing of the starting material powders; sintering the uniaxially pressed starting material powders under an endogas atmosphere or a nitrogen-hydrogen atmosphere at a sintering temperature ranging from 1055° C. to 1152° C.; and heat-treating the sintered material by tempering or annealing.

10. The method according to claim 9, wherein the uniaxial pressing is carried out at a pressure in the range from 40 MPa to 140 MPa, at a temperature ranging from 12° C. to 60° C. and for a time ranging from 0.5 s to 1.8 s.

11. The method according to claim 9, wherein the sintering is carried out at the sintering temperature for a time ranging from 10 min to 30 min.

12. The method according to claim 9, wherein the heat-treating is carried out by tempering.

13. The method according to claim 12, wherein the tempering is carried out by hardening at 850° C. to 950° C., oil-quenching and annealing at 510° C. to 610° C. in this order.

14. The method according to claim 9, wherein the heat-treating is carried out by annealing.

15. The method according to claim 14, wherein the annealing is carried out by heating at 550° C. to 620° C.

16. An internal combustion engine that is partly or completely operated with hydrogen as fuel gas, comprising: a valve; and a layer-sintered valve seat ring including at least two materials, the at least two materials including a function material for a tribological contact with the valve and a support material for the function material; wherein the support material includes: C: 0.5 to 1.8% by weight; Cr: 3 to 16% by weight; Mo: 1 to 5% by weight; W: 0.5 to 5.5% by weight; V: 0.4 to 4.0% by weight; Cu: 12 to 25% by weight; Fe: 41.3 to 82.6% by weight; Mn: up to 0.6% by weight; Si: up to 1.8% by weight; a remainder of production-related contamination in the form of at least one of Ni, Co, Ca, P, and S that are present in contents of <0.3% by weight each.

17. The internal combustion engine according to claim 16, wherein the valve is hardfaced or nitride.

18. The internal combustion engine according to claim 16, wherein the valve is composed of a nickel-based alloy or an iron-based alloy with an Ni content of 10 to 40% by weight.

19. The internal combustion engine according to claim 16, wherein the function material includes: C: 0.7 to 1.5% by weight; Cr: 2 to 4% by weight; Mo: 12 to 18% by weight; W: 2 to 4% by weight; V: 1 to 2% by weight; Cu: 10 to 20% by weight; Co: 6 to 14% by weight; Fe: 34.5 to 66.3% by weight; Mn: up to 1.0% by weight; Si: up to 1% by weight; and a reminder of the function material is production-related contaminations in the form of at least one of Ni, Co, Ca, P and S that are present in contents of <0.3% by weight each.

20. The internal combustion engine according to claim 16, wherein the support material contains: C: 1.0 to 1.8% by weight; Cr: 10 to 15% by weight; Mo: 2.5 to 5% by weight; W: 0.8 to 1.5% by weight; Si: 0.2 to 1.8% by weight; V: 0.4 to 1.5% by weight; Cu: 12 to 25% by weight; Fe: 47.8 to 73.1% by weight; Mn: up to 0.6% by weight; and wherein the remainder are production-related contaminations in the form of at least one of Ni, Co, Ca, P and S that are present in contents of <0.3% by weight each.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0026] There it shows, in each case schematically

[0027] FIG. 1 a sectional representation through a valve seat ring according to the invention having a boundary surface between function material and support material running orthogonally to the valve seat ring axis,

[0028] FIG. 2 a sectional representation through a valve seat ring according to the invention having a boundary surface between function material and support material running non-orthogonally to the valve seat ring axis, and

[0029] FIG. 3 diagrams, which show the overlap between a valve seat ring material and a receiving bore in a cylinder head following engine tests.

DETAILED DESCRIPTION

[0030] According to FIG. 1, a valve seat ring according to the invention comprises a function material (1) and a support material (2) according to an embodiment. A boundary surface (4) running orthogonally to the valve seat ring axis (5) is present between the function material (1) and the support material (2). The angle (6) between the function material (1) and the support material (2) accordingly amounts to 90 °. As shown in FIG. 1, the valve seat ring is fitted into a cylinder head (3) by means of a press fit, which is shown by the press fit boundary surface (7). The overlap of the press fit is usually in the range of 40 .Math.m to 120 .Math.m, preferentially in the range from 50 .Math.m to 110 .Math.m, in particular in the range from 70 .Math.m to 100 .Math.m.

[0031] FIG. 2 shows a valve seat ring according to the invention according to a further embodiment. The valve seat ring according to FIG. 2 is substantially identical with the valve seat ring according to FIG. 1, with the exception that the boundary surface between the function material (1) and the support material (2) runs non-orthogonally to the valve seat ring axis (5). In particular, the angle (6) between the function material (1) and the support material (2) here is smaller than 90°, such as for example between 35° and 70°, preferentially between 45° and 55°. This has the advantage that the contact surface of the support material (2) to the cylinder head (3) is enlarged and the required quantity of the expensive function material (1) can be reduced at the same time, which leads to a lowering of costs.

[0032] The valve seat ring according to the invention can be produced in particular with the following method.

[0033] In a first step, starting material powders for the support material 2 and the function material 1 are produced with compositions as stated above. This is followed by a uniaxial pressing of these starting material powders, preferentially at a pressure in the range from 40 MPa to 140 MPa, at a temperature in the range from 12° C. to 60° C. and for a time in the range from 0.5 s to 1.8 s. Here, one of the starting material powders, prior to the joint final compaction by uniaxial pressing can be subjected to a pre-compaction. By way of this, the boundary surface between the support material and the function material can be pre-adjusted to a desired angle with respect to the valve seat ring axis in the manner shown in FIGS. 1 and 2.

[0034] Following this, the uniaxially pressed starting material powder is sintered under an endogas atmosphere or a nitrogen-hydrogen atmosphere at a temperature in the range from 1055° C. to 1152° C., wherein the sintering is carried out preferentially for a time in the range from 10 min to 30 min.

[0035] Finally, the sintered material is heat-treated by tempering or annealing. The tempering is preferably carried out by hardening at 850° C. to 950° C., oil-quenching and annealing at 510° C. to 610° C. in this order. The annealing is preferably carried out by heating at 550° C. to 620° C.

[0036] The valve seat ring according to the invention is preferably used in a combination with a hard-faced or nitrided valve as opposite runner. Alternatively, the application as valve seat ring can take place combined with a valve of a nickel-based alloy or an iron-based material with an Ni content of 10-40 % by weight as opposite runner.

EXAMPLES

[0037] In the following, examples of the present invention in the form of two fired engine tests are described. Here, the outer diameter each of the valve seat rings after the engine test was measured in three planes and the receiving bore in the cylinder head was likewise measured in three planes. From this the overlap of the respective valve seat ring in the planes was then calculated.

Engine Test 1

[0038] The engine test 1 was a high performance load cycle with a runtime of 1063 hours at a rated output of 260 kW (engine with 7.7 1 cubic capacity). This customer-specific cyclical continuous operation takes place with a high full-load proportion. The support material was a material according to the present Claim 2 and the function material was a material according to the present Claim 5. The angle (6) between the function material and the support material amounted to approximately 90°. The cylinder head material was cast iron with lamellar graphite (GJL). The initial overlap between valve seat ring and cylinder head amounted to 40 to 60 .Math.m and the outer diameter of the valve seat ring amounted to 40.068 ± 0.008 mm. The comparison material was the cast material PL 500. For comparing the material according to the invention with the comparison cast material, the mean value of 4 VSR exhaust valve seat rings each was formed.

Engine Test 2

[0039] The engine test 2 was a customer-specific “cold-warm-continuous operation” with a runtime of 264 hours (engine with 12.81 cubic capacity). The support material was a material according to the present Claim 2 and the function material was a material according to the present Claim 5. The angle (6) between the function material and support material amounted to 60 to 68°. The cylinder head material was cast iron with lamellar graphite (GJL). The initial overlap between valve seat ring and cylinder head amounted to 50 to 70 .Math.m and the outer diameter of the valve seat ring amounted to 43.078 ± 0.008 mm. The comparison material was the sinter material PLS 259. For comparing the material according to the invention with the comparison cast material, the mean value of 3 VSR exhaust valve seat rings each was formed.

[0040] In FIG. 3, the respective overlap is shown in the regions A, B and C of the respective valve seat ring in comparison with a conventional casting material or in comparison with a conventional sinter material. FIG. 3 shows that the overlap after the tests with the material according to the invention is higher than with the respective comparison material.