Abstract: The invention relates to a process for roughening metal surfaces to improve adhesion of layers which are thermally sprayed thereon, in that in a first process step recesses or depressions (2) are introduced into the surface in a material-detaching or material-removing treatment so that the protruding metal of the surface forms raised microstructures (3), in particular projections, ridges, protuberances or bumps, these microstructures being reworked in at least a second process step by shaping and/or breaking so that a significant proportion of the structures form undercuts (4) in relation to the surface.

Abstract: In a process for chip-forming machining of thermally sprayed cylinder barrels of a cylinder crankcase, a cylinder crankcase is cast, those surfaces of the subsequent cylinder barrels which are to be thermally coated are roughened, the cylinder barrels are coated by a thermal spraying process, and the cylinder barrels are remachined to final dimensions. Machining of an insertion bevel and/or an end bevel and/or the cylinder head sealing surface and/or the crankshaft space and/or a cylinder bore is carried out in a chip-forming manner, and a respective chip-forming tool is guided so that the respective cutting edges penetrate into the material which is to be removed from the outside.

Abstract: The invention relates to a process for roughening metal surfaces to improve adhesion of layers which are thermally sprayed thereon, in that in a first process step recesses or depressions (2) are introduced into the surface in a material-detaching or material-removing treatment so that the protruding metal of the surface forms raised microstructures (3), in particular projections, ridges, protuberances or bumps, these microstructures being reworked in at least a second process step by shaping and/or breaking so that a significant proportion of the structures form undercuts (4) in relation to the surface.

Abstract: In a process for processing cylinder crankcases having sprayed cylinder barrels, in which process a cylinder crankcase is cast, those surfaces of the subsequent cylinder barrels which are to be thermally coated are roughened, the cylinder barrels are coated by a thermal spraying process, and the cylinder barrels are remachined to final dimensions. After the thermal spraying process, coating material is at least partially removed from the crankshaft-side part of the cylinder crankcase.

Abstract: In a process for producing a cylinder crankcase having a thermally sprayed cylinder bearing surface, a cylinder crankcase is cast, those surfaces of the subsequent cylinder barrels which are to be thermally coated are roughened, the cylinder barrels are coated by a thermal spraying process, and the cylinder barrels are remachined to their final dimensions. The cylinder crankcase is prefabricated with an oversized dimension in the region of the cylinder head sealing surface.

Abstract: In a process for processing cylinder crankcases having sprayed cylinder barrels, in which process a cylinder crankcase is cast, those surfaces of the subsequent cylinder barrels which are to be thermally coated are roughened, the cylinder barrels are coated by a thermal spraying process, and the cylinder barrels are remachined to final dimensions. After the thermal spraying process, coating material is at least partially removed from the crankshaft-side part of the cylinder crankcase.

Abstract: In a process for producing a thermally coated cylinder bearing surface having an end bevel, a cylinder crankcase is cast, those surfaces of the subsequent cylinder barrels which are to be thermally coated are roughened, the cylinder barrels are coated by a thermal spraying process, and the cylinder barrels are remachined to their final dimensions. The cylinder bore is provided with an end bevel on the crankshaft side.

Abstract: In a process for preparing a cast cylinder bore for thermal coating, a cylinder crankcase is cast, those surfaces of the subsequent cylinder barrels which are to be thermally coated are roughened, the cylinder barrels are coated by a thermal spraying process, and the cylinder barrels are remachined to their final dimensions. The surface of the cylinder bore is roughened by a jet, preferably a water jet and/or liquid jet mixed with solid particles, and material of the cylinder bore is simultaneously removed. A material thickness, which may be between 0.020-0.140 mm but preferably is between 0.004 mm-0.006 mm, is removed during the roughening operation.

Abstract: In a process for fluid blasting cylinder bearing surfaces which are subsequently to be thermally coated, a cylinder crankcase is cast, those surfaces of the subsequent cylinder barrels which are to be thermally coated are roughened, the cylinder barrels are coated by a thermal spraying process, and the cylinder barrels are remachined to their final dimensions. The surfaces of at least two cylinder bores are roughened simultaneously by one jet for each cylinder bore.

Abstract: In a process for thermal spraying of cylinder bearing surfaces of multi-line engines, a cylinder crankcase having at least two lines of cylinders is cast, those surfaces of subsequent cylinder barrels which are to be thermally coated are roughened, the cylinder barrels are coated by a thermal spraying process, and the cylinder barrels are remachined to their final dimensions. During thermal spraying, a shielding template is introduced in the region of the crankshaft space at least between a cylinder which is currently being thermally coated and an opposite cylinder of an adjacent line of cylinders.

Abstract: In a process for preparing cylinder bearing surfaces which are to be thermally sprayed, in which process a cylinder crankcase is cast, those surfaces of the subsequent cylinder barrels which are to be thermally coated are roughened, the cylinder barrels are coated by a thermal spraying process, and the cylinder barrels are remachined to their final dimensions. The surface of a cylinder barrel is roughened by a jet, preferably a water jet and/or a liquid jet mixed with solid particles. Before a blasting lance is introduced into the cylinder barrel, the jet is switched on outside the barrel and is only introduced into the bore after a predeterminable stabilization time.

Abstract: In a process for producing a thermally coated cylinder bearing surface having an insertion bevel, a cylinder crankcase is cast, those surfaces of the subsequent cylinder barrels which are to be thermally coated are roughened, the cylinder barrels are coated by a thermal spraying process, the cylinder bore is bevelled, and the cylinder barrels are remachined to their final dimensions. The cylinder crankcase is prefabricated with an oversized dimension in the region of the cylinder head sealing surface, and the insertion bevel for the cylinder bore is introduced into the cylinder head sealing surface which has the oversized dimension.

Abstract: In a process for chip-forming machining of thermally sprayed cylinder barrels of a cylinder crankcase, a cylinder crankcase is cast, those surfaces of the subsequent cylinder barrels which are to be thermally coated are roughened, the cylinder barrels are coated by a thermal spraying process, and the cylinder barrels are remachined to final dimensions. Machining of an insertion bevel and/or an end bevel and/or the cylinder head sealing surface and/or the crankshaft space and/or a cylinder bore is carried out in a chip-forming manner, and a respective chip-forming tool is guided so that the respective cutting edges penetrate into the material which is to be removed from the outside.

Abstract: In a process for casting a metallic semi-finished product into a casting, the semi-finished product is roughened on a surface which faces the casting, then being placed in a defined position in a casting mold and surrounded with casting metal, after which a firm bond is formed between the semi-finished product and the solidified casting metal at the roughened surface. The surface of the semi-finished product is roughened by high-pressure water blasting.

Abstract: In a process for casting a metallic semi-finished product into a casting, the semi-finished product is roughened on a surface which faces the casting, then being placed in a defined position in a casting mold and surrounded with casting metal, after which a firm bond is formed between the semi-finished product and the solidified casting metal at the roughened surface. The surface of the semi-finished product is roughened by high-pressure water blasting.