Method for manufacturing a metal component, metal component, and turbocharger

Patent metadata

Field	Value
Publication number	US-2017370003-A1
Application number	US-201615548107-A
Country	US
Kind code	A1
Filing date	Jan 21, 2016
Priority date	Feb 3, 2015
Publication date	Dec 28, 2017
Grant date	—

Abstract

A turbocharger compressor wheel with an aluminum proportion of at least 50 atom percent, produced by. etching a turbine wheel base body using an alkaline etchant to produce a specific etch pitting consisting of nano pores and micropores and chemical deposition of a nickel-phosphorous protective layer ( 19 ) onto the etched base body surface.

First claim

1 . A method for manufacturing a compressor wheel ( 17 ) for a turbocharger ( 1 ), the compressor wheel ( 17 ) comprising a base body and a nickel-phosphorous protective coating, the method comprising the steps:
etching the base body using an alkaline etchant to produce a specific etch pitting, wherein said specific etch pitting consists of nano etch pittings and micro etch pittings, wherein the nano etch pittings have a depth of 0.1 to 1.5 μm and micro etch pittings have a depth of 4 to 12 μm, and chemical deposition of a nickel-phosphorous protective layer ( 19 ) onto the etched metal surface, wherein the nickel-phosphorous protective layer comprises phosphorous, antimony and nickel.

2 . The method according to claim 1 , wherein the etching is carried out in an etching bath.

3 . The method according to claim 2 , wherein a temperature of the etching bath lies between 50 and 80° C.

4 . The method according to claim 2 , wherein an immersion time of the base body into the etching bath is between 20 and 40 seconds.

5 . The method according to claim 2 , wherein a dwell time of the base body in the etching bath is 60 to 110 seconds.

6 . The method according to claim 2 , wherein the base body is moved in the etching bath in a radially extending circular path.

7 . The method according to claim 6 , wherein a rotational speed of the base body in the etching bath is 10-15 rpm.

8 . The method according to claim 1 , wherein a coating composition is used for the chemical deposition which contains nickel ions, more than 10.3 wt. %, of phosphorous, and more than 0.3 wt. % of antimony, maximum 0.5 wt. % antimony, in each case relative to the total weight of the coating composition.

9 . The method according to claim 1 , wherein the base body is treated with a nitric acid solution prior to the chemical deposition of the nickel-containing layer.

10 . The method according to claim 1 , wherein the base body is formed from AlCuMgNi or AlCu 2 MgNi.

11 . A compressor wheel ( 17 ) for a turbocharger ( 1 ), the compressor wheel ( 17 ) having a base body and a nickel-phosphorous protective coating ( 19 ), the base body having an aluminum proportion of at least 50 atom percent, the base body having a specific etch pitting, wherein said specific etch pitting consists of nano etch pittings and micro etch pittings, wherein the nano etch pittings have a depth of 0.1 to 1.5 μm and micro etch pittings have a depth of 4 to 12 μm, and wherein the nickel-phosphorous protective coating ( 19 ) contains nickel, phosphorous, and more than 0.3 wt. % of antimony relative to the total weight of the coating composition.

12 . The compressor wheel according to claim 11 , wherein the coating ( 19 ) has a layer thickness variation of maximum±1.5 μm and a layer thickness of the coating ( 19 ) of approximately 20 μm.

13 . (canceled)

14 . (canceled)

15 . The compressor wheel according to claim 11 , wherein a volume ratio of the nano pittings to the micro pittings is 15:1 through 20:1.

16 . A turbocharger comprising the compressor wheel according to claim 11 .

17 . A compressor wheel according to claim 11 , wherein the coating composition is comprised of more than 10.3 wt. % phosphorous, and more than 0.3 wt. % of antimony, balance nickel, in case relative to the total weight of the coating composition.

18 . A compressor wheel according to claim 11 , wherein the coating composition is comprised of more than 10.5 wt. % phosphorous, and more than 0.3 wt. % but maximum 0.5 wt % antimony, balance nickel, in each case relative to the total weight of the coating composition.

Assignees

• Borgwarner Inc

Inventors

• Schall Gerald
• Cempirkova Daniela
• Urlberger Hermann H
• Donchev Alexander

Classifications

• C23C18/1637

  metallic substrate · CPC title

• F05D2220/40

  in turbochargers · CPC title

• C23C18/32

  Coating with nickel, cobalt or mixtures thereof with phosphorus or boron (C23C18/50 takes precedence) · CPC title

• F04D29/284

  for compressors · CPC title

• C23C18/1827 Primary

  only one step pretreatment · CPC title