EP0075844A2
Expired / Lapsed
EP
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Heat resisting and insulating light alloy articles and method of manufacture
Assignee: Toyota Motor Corp
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Filing: 1982-09-21
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Granted: —
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Expires: 2002-09-21
Abstract
Abstract Light alloy articles comprising a body of light alloy having a composite fiber/light alloy layer, a sprayed heat-resistant alloy layer, and a sprayed ceramic base layer formed on the body in this sequence exhibit improved heat resistance and insulation and are very useful in the manufacture of internal combustion engine pistons. A method for producing such a coated light alloy article by spraying is also provided.
Inventors
- 👤 Tadashi Donomoto
- 👤 Mototsugu Koyama
- 👤 Masaaki Nagaoka
Bibliographic Details
Application Number
—
Jurisdiction
EP
Data Source
google_patents
Last Synchronized
2026-10-25 20:27
CPC Classifications
F; F02; F02B; F02B77/00; F02B77/11; C; C23; C23C; C23C4/00; C23C4/02; F02F; F02F3/00; F02F3/10; F02F3/12; F02F7/00; F02F7/0085; F02F7/0087; F02B3/00; F02B3/06; F02F2200/00; F02F2200/04; F05; F05C; F05C2201/00; F05C2201/02; F05C2201/021; F05C2201/028; F05C2201/04; F05C2201/0433; F05C2201/0448; F05C2201/046; F05C2251/00; F05C2251/04; F05C2251/042; F05C2253/00; F05C2253/16; Y; Y10; Y10T; Y10T29/00; Y10T29/49; Y10T29/4998; Y10T29/49988; Y10T428/00; Y10T428/12; Y10T428/12014; Y10T428/12021; Y10T428/12028; Y10T428/12063
Claims Analysis
Total Claims: 20
Claim 1
Independent Claim
129 words
A heat resisting and insulating light alloy article comprising a body of a light alloy, a composite fiber/light alloy layer formed on the body, the composite layer being made essentially of a light alloy of the same type as the light alloy of which the body is made and heat-resistant fibers having a lower heat conductivity than the light alloy, said fibers being integrally bonded by the light alloy, a first layer of a heat-resisting alloy sprayed onto said composite layer, and a second layer of a ceramic base material sprayed onto said first layer, wherein the heat-resisting alloy of which said first layer is made is, in coefficient of thermal expansion, higher than the ceramic material of the second layer and lower than the composite fiber/light alloy layer.
Claim 2
Dependent Claim
129 words
A heat resisting and insulating light alloy article comprising a body of a light alloy, a composite fiber/light alloy layer formed on the body, the composite layer being made essentially of a light alloy of the same type as the light alloy of which the body is made and heat-resistant fibers having a lower heat conductivity than the light alloy, said fibers being integrally bonded by the light alloy, a first layer of a heat-resisting alloy sprayed onto said composite layer, and a second layer of a ceramic base material sprayed onto said first layer, wherein the heat-resisting alloy of which said first layer is made is, in coefficient of thermal expansion, higher than the ceramic material of the second layer and lower than the composite fiber/light alloy layer.
Claim 3
Dependent Claim
22 words
The article according to claim 1 wherein said light alloy is selected from the group consisting of aluminum alloys and magnesium alloys.
Claim 4
Dependent Claim
53 words
The article according to claim 1 wherein said fiber is selected from the group consisting of Al 2 O 3 fiber, ZrO 2 fiber, SiC fiber, Al 2 O 3 -SiO 2 fiber, glass fiber, carbon fiber, boron fiber, stainless steel fiber, SiC whisker, Si 3 N 4 whisker, and potassium titanate whisker.
Claim 5
Dependent Claim
23 words
The article according to claim 1 wherein said heat-resisting alloy is selected from the group consisting of Ni-Cr alloy, Ni-Cr-Al alloy, Ni-Cr-Al-Y alloy.
Claim 6
Dependent Claim
35 words
The article according to claim 1 wherein said ceramic material selected from the group consisting of Zr0 2 , A1 2 0 3 , M g O, Cr 2 0 3 , and mixtures thereof.
Claim 7
Dependent Claim
29 words
The article according to claim 1 wherein the concentration of fibers in said composite fiber/light alloy layer increases continuously from its interface with the body toward the second layer.
Claim 8
Dependent Claim
29 words
The article according to claim 1 wherein the concentration of fibers in said composite fiber/light alloy layer increases stepwise from its interface with the body toward the second layer.
Claim 9
Dependent Claim
17 words
The article according to claim 1 wherein said second layer is made solely of a ceramic material.
Claim 10
Dependent Claim
47 words
The article according to claim 1 wherein said second layer is a composite layer of a ceramic material and a heat-resisting alloy of the same type as the heat-resisting alloy of which said first layer is made, said ceramic material and said heat-resisting alloy being concurrently sprayed.
Claim 11
Dependent Claim
30 words
The article according to claim 9 wherein the concentration of the ceramic material in said second layer increases continuously from its interface with said first layer to its exposed surface.
Claim 12
Dependent Claim
30 words
The article according to claim 9 wherein the concentration of the ceramic material in said second layer increases stepwise from its interface with said first layer to its exposed surface.
Claim 13
Independent Claim
127 words
A method for producing a heat resisting and insulating light-alloy article comprising the steps of placing a preform of heat-resistant fibers at a given position in a cavity of a mold, pouring a molten light alloy into the mold cavity, subjecting the molten light alloy in the mold cavity to liquid metal forging, thereby causing the light alloy to fill up the space among the fibers of the preform, allowing the light alloy to solidify to form a block of the light alloy having a composite fiber/light alloy layer integrated on its surface, removing the block from the mold, spraying a heat-resisting alloy onto the composite fiber/light alloy layer on the block, and further spraying a ceramic base material onto the sprayed layer of the heat-resisting alloy.
Claim 14
Independent Claim
127 words
A method for producing a heat resisting and insulating light-alloy article comprising the steps of placing a preform of heat-resistant fibers at a given position in a cavity of a mold, pouring a molten light alloy into the mold cavity, subjecting the molten light alloy in the mold cavity to liquid metal forging, thereby causing the light alloy to fill up the space among the fibers of the preform, allowing the light alloy to solidify to form a block of the light alloy having a composite fiber/light alloy layer integrated on its surface, removing the block from the mold, spraying a heat-resisting alloy onto the composite fiber/light alloy layer on the block, and further spraying a ceramic base material onto the sprayed layer of the heat-resisting alloy.
Claim 15
Dependent Claim
18 words
The method according to claim 12 wherein the spraying of heat-resisting alloy is carried out by plasma spraying.
Claim 16
Dependent Claim
18 words
The method according to claim 12 wherein the spraying of ceramic material is carried out by plasma spraying.
Claim 17
Dependent Claim
30 words
The method according to claim 12 wherein the spraying of ceramic material is started during the spraying of heat-resisting alloy after the heat-resisting alloy layer has reached a predetermined thickness.
Claim 18
Dependent Claim
44 words
The method according to claim 15 wherein the concurrent spraying of heat-resisting alloy and ceramic material is controlled such that the resulting heat-resisting alloy/ceramic material layer increases the concentration of ceramic material from the interface with the heat-resisting alloy layer to the exposed surface.
Claim 19
Dependent Claim
20 words
. The method according to claim 12 which further comprises the step of previously forming heat-resistant fibers into the preform.
Claim 20
Dependent Claim
29 words
The method according to claim 17 wherein the preforming step is controlled such that the fiber packing density increases from one surface to the opposite surface of the preform.
References Cited (Backward Citations)
No citation records indexed.
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