Method of honing high-porosity cylinder liners

Patent metadata

Field	Value
Publication number	US-10267258-B2
Application number	US-201615369013-A
Country	US
Kind code	B2
Filing date	Dec 5, 2016
Priority date	Dec 5, 2016
Publication date	Apr 23, 2019
Grant date	Apr 23, 2019

Abstract

Methods of honing a surface are disclosed. The method may include spraying a coating having an initial average bulk porosity onto an engine bore wall and honing the coating to create an intermediate honed surface. The method may then include cleaning the intermediate honed surface and honing the intermediate honed surface with a cutting force of, for example, 110-130 kgf after the cleaning step. This may create a honed surface having an average porosity greater than the initial average bulk porosity. The methods may create a honed surface having a porosity that is more porous than the initially sprayed coating. The increased porosity of the honed surface may allow for increased oil retention in, for example, engine bores.

First claim

What is claimed is:

1. A method, comprising:
spraying a coating having an initial average bulk porosity onto an engine bore wall;
honing the coating to create an intermediate honed surface;
cleaning the intermediate honed surface; and
honing the intermediate honed surface with a cutting force of 110-130 kgf after the cleaning step to create a honed surface having an average porosity greater than the initial average bulk porosity.

2. The method of claim 1 , wherein honing the intermediate honed surface creates a honed surface having an average porosity that is at least 2% greater than the initial average bulk porosity.

3. The method of claim 1 , wherein honing the intermediate honed surface creates a honed surface having an average porosity that is at least 5% greater than the initial average bulk porosity.

4. The method of claim 1 , wherein the cleaning step generates nucleation sites in the intermediate honed surface and honing the intermediate honed surface after the cleaning step removes material from the nucleation sites to create new pores.

5. The method of claim 1 , wherein the cleaning step includes spraying a pressurized liquid or a solid onto the intermediate honed surface or brushing the intermediate honed surface.

6. The method of claim 1 , wherein the cutting force is 115-125 kgf.

7. The method of claim 1 , wherein the cutting force is about 120 kgf.

8. The method of claim 1 , wherein the initial average bulk porosity is from 0.1-3% and the average porosity of the honed surface is 5-20%.

9. A method, comprising:
spraying a coating comprising a plurality of particles onto an engine bore wall, the coating having an initial average bulk porosity;
honing the coating to create an intermediate honed surface;
cleaning the intermediate honed surface to remove debris from pores in the intermediate honed surface and to loosen a portion of the particles in the coating; and
honing the intermediate honed surface after the cleaning step to remove particles loosened in the cleaning step and create a honed surface having an average porosity greater than the initial average bulk porosity.

10. The method of claim 9 , wherein honing the intermediate honed surface creates a honed surface having an average porosity that is at least 2% greater than the initial average bulk porosity.

11. The method of claim 9 , wherein honing the intermediate honed surface creates a honed surface having an average porosity that is at least 5% greater than the initial average bulk porosity.

12. The method of claim 9 , wherein the cleaning step includes spraying a pressurized liquid onto the intermediate honed surface.

13. The method of claim 9 , wherein the cleaning step includes spraying a solid material onto the intermediate honed surface.

14. The method of claim 9 , wherein the cleaning step includes mechanically brushing the intermediate honed surface.

15. The method of claim 9 , wherein the honing of the intermediate honed surface is performed using a cutting force of 110-130 kgf.

16. The method of claim 15 , wherein the cutting force is 115-125 kgf.

17. The method of claim 9 , wherein the initial average bulk porosity is from 0.1-3% and the average porosity of the honed surface is 5-20%.

18. The method of claim 1 , wherein the engine bore wall is formed of aluminum.

19. The method of claim 9 , wherein the engine bore wall is formed of aluminum.

20. The method of claim 15 , wherein the cutting force is 120 kgf.

Assignees

• Ford Global Tech Llc

Inventors

• Maki Clifford E
• Beyer Timothy George
• Gangopadhyay Arup Kumar
• Ghaednia Hamed
• Elie Larry Dean
• Boileau James Maurice

Classifications

• B24B33/02 Primary

  designed for working internal surfaces of revolution, e.g. of cylindrical or conical shapes · CPC title

• C23C4/134

  Plasma spraying · CPC title

• F02F2200/00

  Manufacturing · CPC title

• C23C4/18 Primary

  After-treatment · CPC title

• F02F1/004 Primary

  Cylinder liners (F02F1/08, F02F1/16 take precedence) · CPC title