Spiny Cylinder Liner (e)

8/18/2019 Spiny Cylinder Liner (e)

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C O A T I N G S

F I L T R A T I O N

F E E D I N G S Y S T E M S

M E L T S H O P R E F R A C T O R I E S

M E T A L L U R G I C A L A N D P O U R I N G C O N T R O L

B I N D E R S

C R U C I B L E S

HIGH PERFORMANCE WATER-BASED DIE COATINGS

Coatings for high performance cylinder liners

+ Reduced scrap and rework

+ No machining of the outer surface

+ Superior casting quality

+ Higher productivity


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Cylinder liners are incorporated into the borearea of internal combustion engines to providea suitably robust companion to the piston andrequire good sliding properties, wear resistanceand thermo-mechanical behaviour during operation.Pre-manufactured cylinder liners can be cast into orphysically inserted into aluminium engine blocks forautomotive applications or produced as a replaceablecomponent in larger diesel blocks.

Coatings for cylinder liner manufacturefor the highest quality demands of the modern foundry

Typically cylinder liners are produced in grey oralloyed-grey iron using the centrifugal casting process,in which liquid metal is poured into a horizontallyrotating steel die to which a protective coating hasbeen applied.

+ High integrity castings + Controlled solidication + Excellent surface nish + High productivity

Cylinder liners can vary significantly in weight anddimension; from single liners weighing tens ofkilograms to thin walled tubes with lengths up to anumber of metres that are subsequently cut into manysmall lengths. From a coatings perspective there aretwo main classifications based on the external surfacefinish requirements.

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Centrifugal casting machine (Courtesy Gibson Centritech Ltd.)Engine block to demonstrate Foseco liner technology


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Coatings for Smooth Cylinder Liners

i. Smooth – to provide an optimum surface for subsequent machining operationsa flat, clean surface is required.ii. Textured – for cast-in applications for the production of aluminium engine blocksthe preferred surface finish has a rough or spiny profile allowing the cast iron linerto be keyed into the surrounding aluminium.

Blank 50kg cast liner for large diesel engine application

For the manufacture of cast iron cylinder liners withan externally smooth surface nish the standardSPUNCOTE range of coatings have excellentrheological properties that provide good suspensionwithin the pressure pot of the spray unit and idealcharacteristics for spraying, ensuring an even, smoothlayer can be applied to the heated die. The refractoryller materials have been blended to ensure optimumpermeability to ensure fast drying of the coatingwhen applied to the hot die, without spalling or theformation of craters or blisters, ensuring the cast

surface is free from blemishes or entrapped coatingmaterial.

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The choice of refractory llers and the build-up oflayer thickness on application in combination withdie temperature control during casting inuences thesolidication rate of the metal and the subsequentmetallurgical structure.

Refractory binders are also incorporated into theformulation to ensure that the coating layer remainslightly adhered to the cast component, improving thecasting release from the die and ensuring that themajority of used coating is extracted with the casting

from the die, reducing die cleaning times within theproduction cycle.

i. ii.


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*FOSECO and the Logo are trade marks of the Vesuvius Group, registered in certain countries, used under licence. All rights reserved. No part of this publication may be reproduced, stored in a retrieval system ofany nature or transmitted in any form or by any means, including photocopying and recording, without the written permission of the copyright holder or as expressly permitted by law. Applic ations for permissionshall be made to the publisher at the address mentioned.Warning: The doing of an unauthorised act in relation to a copyright work may result in both a civil claim for damages and criminal prosecution. All statement, information and data contained herein are publishedas a guide and although believed to be accurate and reliable (having regard to the manufacturer’s practical experience) neither the manufacturer, licensor, seller nor publisher represents nor warrants, expresslyor impliedly: (1) their accuracy/reliability, (2) that the use of the product(s) will not infringe third party rights, (3) that no further safety measures are required to meet local legislation. The seller is not authorisedto make representations nor contract on behalf of the manufacturer/licensor. All sales by the manufacturer/seller are based on their respective conditions of sale available on request.© Foseco International Limited 05/11.

Foseco International LimitedDrayton Manor Business Park,Tamworth, Staffordshire,England B78 3TLPhone: +44 (0)1827 262021Fax: +44 (0)1827 283725www.foseco.comPlease contact your local Foseco team

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For cylinder liners that will be subsequently cast intoaluminium engine blocks, the provision of a texturedsurface to the end-user specification is required.The textured surface keys into the aluminium duringthe casting process ensuring there is no lateral orradial movement during operation. However it isalso essential that the aluminium attains an intimatecontact with the liner without voids, as such voidswill lead to localised variance in heat transfer withinthe cylinder leading to distortion, excessive wear andreduced lifespan. Generally a fine, rough surfaced

cylinder liner can only be used for casting aluminiumblocks by the high-pressure.

The textured, high performance Foseco liner is suitablefor gravity die casting without further treatments,such as thermal spraying, being required.

Coatings for Textured Cylinder LinersFoseco Performance Liner Technology

C O M M I T T E D T O F O U N D R I E S

Comparison micrograph of interface rough vs. textured liner

Foseco’s Technology Package for Iron Cylinder Liners

Process controlFor the optimised manufacture of cylinder liners,Foseco offer a full package of service and producttechnologies to ensure best-in-class melting,metallurgical control, metal transfer and die coatingapplications. Please contact your local Foseco teamfor further information and a detailed introduction toour cylinder liner manufacturing process expertise.

SPUNCOTE BENEFITS

+ Low sedimentation + Good layer build up + Smooth surface finish + Low spalling + Easy casting removal + Easy cleaning of die

ADDITIONAL SPUNCOTE SP BENEFITS

+ Textured surface finish + Cylinder liners suitable for gravity,

low and high pressure die casting

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Spiny Cylinder Liner (e)