Element comprising at least one sliding surface having a coating for use in an internal combustion engine or a compressor

Abstract

An element with at least one slide surface with a coating for use on an internal combustion engine may include a base of a metallic alloy and at least one inner surface provided with a hard ceramic coating generated by physical vapor deposition. The element may include a porosity with a rate lower than 2 percent by volume, a Vickers hardness ranging from 1500 to 3000HV, and a compressive inner tension lower than 500 MPa.

Claims

1. An element provided with at least one slide surface with a coating for use on an internal combustion engine, the element comprising: a base of steel or cast iron; and at least one inner surface provided with a hard ceramic coating generated by physical vapor deposition, wherein: the element includes a porosity with a rate lower than 2% by volume, Vickers hardness ranging from 1500 to 3000 HV, and compressive inner tension lower than 500 MPa; and the physical vapor disposition is achieved by high power impulse magnetron plasma (HIPIMS), and the base is polarized with negative potential.

2. The element according to claim 1, wherein the ceramic coating comprises nitrides formed by at least one of chrome, titanium, niobium, molybdenum, or aluminum.

3. The element according to claim 1, wherein the coating includes porosity at a rate lower than 0.5 percent by volume.

4. The element according to claim 1, wherein the coating includes compressive inner tension lower than 200 MPa.

5. The element according to claim 1, wherein the coating includes a thickness ranging from 5 to 100 μm.

6. The element according to claim 1, wherein the base includes cast iron.

7. The element according to claim 1, wherein the base includes steel.

8. The element according to claim 1, wherein the base includes aluminum.

9. The element according to claim 1, wherein the element includes at least one of a piston ring, a tappet, a valve, a lob, and a bearing.

10. A coating, comprising: a base material having a least one ceramic slide surface disposed thereon, wherein the slide surface includes a porosity with a rate lower than 2 percent by volume, Vickers hardness ranging from 1500 to 3000 HV, and compressive inner tension lower than 500 MPA.

11. The coating according to claim 10, wherein the slide surface comprises nitrides formed by at least one of chrome, titanium, niobium, molybdenum, or aluminum.

12. The coating according to claim 10, wherein the slide surface has porosity having a rate lower than 0.5 percent by volume.

13. The coating according to claim 12, wherein the slide surface has compressive inner tension lower than 200 MPa.

14. The coating according to claim 13, wherein the slide surface comprises a thickness ranging from 5 to 100 μm.

15. The coating according to claim 10, wherein at least one of the base is polarized with negative potential and includes at least one of cast iron, steel, and aluminum.

16. A method for manufacturing an element with at least one sliding surface, comprising: providing a base of a metallic alloy; and generating a ceramic coating disposed on the base via physical vapor deposition, wherein the physical vapor deposition is achieved by high power impulse magnetron plasma sputtering; wherein the coating includes a porosity with a rate lower than 2 percent by volume, Vickers hardness ranging from 1500 to 3000 HV, and compressive inner tension lower than 500 MPa.

17. The method according to claim 16, wherein the coating includes a porosity having a rate lower than 0.5 percent by volume.

18. The method according to claim 16, wherein the coating includes compressive inner tension lower than 200 MPa.

19. The method according to claim 16, wherein the coating has a thickness ranging from 5 to 100 μm.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) The present invention will now be described in greater detail with reference to an example of embodiment represented in the drawings. The figures show:

(2) FIG. 1 is a graph that shows a relationship between the increase in compressive inner tension in a chrome-nitride coating;

(3) FIG. 2 is a graph that shows the wear coefficient (m.sup.3/Nm) of a chrome-nitride coating as a function of different types of PVD deposition, carried out at a velocity of 10 cm/min;

(4) FIG. 3 is a view of two elements that work sliding, one of them being provided with a chrome-nitride coating with equiaxial morphology of the present invention.

DETAILED DESCRIPTION

(5) The present invention relates to the innovatory possibility of dominating the inner tensions of a coating regardless of its thickness, thus enabling one to carry out coatings with thicknesses larger than the conventional ones and to increase the resistance to wear of such ceramic coatings nitrided with the physical vapour deposition (PVD) process.

(6) The properties of a coating deposited by the physical vapour deposition vary much as a function of the energy applied to the positive ions, for example, Cr.sup.+ and N.sup.+, during the deposition process.

(7) As discussed before, present-day processes of nitrided ceramic coating on elements 1 that works sliding on internal combustion engines exhibit limitations with regard to the tribological performance because of their high compressive inner tension.

(8) The present invention provides a solution to this problem by promoting the growth of a coating 4 without increasing the compressive inner tension of the coating 4.

(9) It should be noted that the elements 1 that work sliding may comprise various components of an engine that undergo contact, a friction relationship resulting between them. Thus, the coating 4 of the present invention can be applied to one of two elements or simultaneously to both elements that will interact with each other.

(10) The element 1 that works sliding of the present invention comprises a base 2 of a given metallic alloy and an outer surface 3, which will receive the coating 4 (see FIG. 3). The base 2 may be constituted by a ferrous alloy or by steel, as for example steel containing from 10 to 17% chrome (stainless steel), aluminum, among others.

(11) Examples of elements 1 that work sliding of the present invention are found on piston rings, both compression and oil ones, cylinders and cylinder sleeves, pistons, bearings and segments, tappets and cams, among numberless others.

(12) The coating 4 of the present invention is based on the deposition of a coating 4 on at least one surface of an element 1 that works sliding by a PVD process, more concretely through high power impulse magnetron sputtering, hereinafter called HIPIMS.

(13) The new HIPIMS deposition method for elements 1 that work sliding enables one to ionize the material, generally a metallic material (Cr, Ti, Mo, Nb, Al, etc.), before conversion to nitride. In turn, the acceleration of the metallic ions with high energy against the coating 4 surface enables one to achieve, in a surprising manner, relaxation of the coating 4 during its growth without loss of its hardness.

(14) It should be noted that this behavior (high hardness and low inner tensions of the coating) is not obvious, being, by the way, antagonistic with respect to the prior art. Anyway, this is a highly desired result for obtaining extraordinary resistance to wear. Upon being stressed by an outer loading (due to the application as a component of a machine or of an internal combustion engine, for example), a coating will be subjected to the generation of tensions resulting from the loading and, therefore, the lesser the initial tension of the coating the bigger the loading which it will bear, until a tension that causes rupture of the coating 4 (crack nucleation and growth thereof) is reached.

(15) A preferred example of the present invention may is represented by FIG. 3. Supposing that the figure deals with a piston ring and a cylinder of an internal combustion engine (both elements 1 that work sliding), one can coat only one or both elements 1 that work sliding. In the present case, we will dwell on a classic example in which a piston ring, for mounting on any of its grooves, receives the coating 4 of the present invention on the surface that will contact the cylinder wall.

(16) Preferably, but not compulsorily, the ceramic coating 4 is of chrome nitride, but other metallic elements may be used forming the ceramic coating, among which titanium, molybdenum, niobium, aluminum, etc., or a mixture thereof may be employed.

(17) The coating 4 is deposited by the HIPIMS process with the base 2 (substrate) polarized with negative potential, and it is possible to achieve compressive inner tension values ranging from 0 to 500 MPa, but the values should preferably range from 0 to 200 MPa. The characteristic particularities of the HIPIMS deposition process enable one to achieve Vickers hardness ranging from 1000 HV to 3000 HV. It should be noted that this range is higher than the prior-art values, the value 3000 HV being surprisingly high. Additionally, the present invention manages to promote coating 4 thicknesses ranging from 5 μm to 100 μm, a value that is frankly high when compared with the prior art, so much so in the cases where the coating is based on titanium nitride, a coating that usually exhibits a limited thickness due to its high tension.

(18) As a natural result of the high energy of the ions that form the coating 4, particularity of the HIPIMS process, there is a significant densification of the coating 4, resulting in a reduction of porosity and an excellent adhesion of the ions on the base 2. Porosity values are below 2% by volume, the preferred range for this invention being below 0.5%, a value that is really reduced with respect to the prior art when one takes into consideration that simultaneously the hardness and inner tension values are excellent.

(19) Additionally, this process enables another advantage, enabling the growth of the coating 4 free of droplets (microparticles). As a result, the HIPIMS process for deposition of coatings 4 enables one to achieve excellent tribological properties, such as resistance to wear and to detachment.

(20) The graph of FIG. 2 makes the difference of results obtained by said PVD processes clearly evident. FIG. 2 shows results of tests of the wear coefficient of a chrome-nitride coating as a function of different deposition methods of the prior art. One cites the deposition via sputtering of the target material with unbalanced magnetron (UBM) and Arc with respect to HIPIMS of the present invention. It is evident that the present process achieves resistance to wear more than twice as high as the prior art, without leaving margin for doubt that, in spite of being surprising, the HIPIMS coating 4 of the present invention is capable of generating very positive results for elements 1 that work sliding for use on internal combustion engines.

(21) By virtue of the excellent results achieved, the present technology reaches the standard required for operating in the next few generations of engines, especially on engines with exhaust gas recirculation and selective catalytic reduction, thus contributing to the reduction of emission of pollutants.

(22) Thus, it is clear that the coating 4 of the present invention proposes an unexpected relationship between the growth of a coating and its inner tension, since one manages to obtain a coating having high tribological properties and thicknesses that are not normally practiced by conventional techniques, thus generating a resistance to wear that is superior to that of any coating obtained by the PVD process of the prior art.

(23) A preferred example of embodiment having been described, one should understand that the scope of the present invention embraces other possible variations, being limited only by the contents of the accompanying claims, which include the possible equivalents.