Abstract: A thermally coated component is disclosed. The thermally coated component has a frictionally optimized surface of a track for a friction partner, where the surface has pores. The pores have an entry rounding, the slope of which, as a ratio of the depth of the entry rounding to a longitudinal section of the surface or parallel to the surface, has a value of more than 2.5 ?m/mm.

Abstract: A method for coating a substrate in which a wire-like spray material based on iron is melted in an electric arc and is isolated as a layer on the substrate is disclosed. The following alloy components are contained in the spray material: carbon: 0.1% by weight to 0.3% by weight; manganese: 1.5% by weight to 2.0% by weight; and silicon: 0.25% by weight to 0.4% by weight, respectively with regard to a total weight. The substrate is an aluminium alloy and the surface thereof is roughened mechanically before the coating in such a way that a roughness is formed with undercuts which are filled with the spray material over the course of the coating and therefore a cause a mechanical interlocking of the coating with the substrate. The coating is removed on the surface. An electric arc wire sprayed layer based on iron on the substrate is also disclosed.

Abstract: A thermally coated component that has a frictionally optimized surface of a raceway for a frictional counterpart. The frictionally optimized surface has a theoretical oil retention volume VOil of 10 to 800 ?m3/mm2, which can be pre-determined by a component coating surface simulation. A method for the component coating surface simulation of a thermally coated component is furthermore disclosed, with parameter determination for surface structures of the component coating surface, wherein a parameter simulates a function between the component coating surface and the frictional counterpart.

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 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 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 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 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 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 concerns a 3D milling machine and a 3D milling process. The milling machine comprises a milling unit (2) with a motor driven work spindle (4) for receiving a milling tool, a work table for clamping work pieces, guide and drive device for producing relative movement of the milling unit and the work table in at least three spatial directions, and a laser device (12) for emitting a laser beam. A laser assisted milling of free-form surfaces is made possible in that the milling unit is a spherical cutter (6), further, that a mounting device (30, 32) and a driving device (36, 38) are provided for producing a precise movement of the laser emitter (12) about a point on the beam axis, such that the laser beam (14) circles about a central axis, which intersects the axis of the work spindle (4) at an acute angle, as well as a mounting device and a driving device for at least one of pivoting and rotating of the work table (18) about at least one axis.

Abstract: The invention concerns a 3D milling machine and a 3D milling process. The milling machine comprises a milling unit (2) with a motor driven work spindle (4) for receiving a milling tool, a work table for clamping work pieces, guide and drive means for producing relative movement of the milling unit and the work table in at least three spatial directions, and a laser device (12) for emitting a laser beam. A laser assisted milling of free-form surfaces is made possible in that the milling unit is a spherical cutter (6), further, that mounting means (30, 32) and drive means (36, 38) are provided for producing a precise movement of the laser emitter (12) about a point on the beam axis, such that the laser beam (14) circles about a central axis, which intersects the axis of the work spindle (4) at an acute angle, as well as mounting means and drive means for at least one of pivoting and rotating of the work table (18) about at least one axis.