Abstract: A wire-form spray material, in particular for arc wire spraying, essentially comprising iron. The spray material is formed at least with carbon as a microalloy such that upon solidification of the spray material a fine pearlitic, bainitic, martensitic structure arises in which finely dispersed nitrides are present.

Abstract: A wire-like spray material (4) based on an iron for electric arc wire spraying and also a functional layer (2) which can be produced therewith on a substrate (1). The functional layer (2) has good corrosion resistance towards diesel fuel having a high sulphur content.

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: A wire-form spray material, in particular for arc wire spraying, essentially comprising iron. The spray material is formed at least with carbon as a microalloy such that upon solidification of the spray material a fine pearlitic, bainitic, martensitic structure arises in which finely dispersed nitrides are present.

Abstract: The invention relates to an inner burner (1) for electric arc wire spraying of hollow spaces, particularly cylinder bearing surfaces (9), comprising two meltable electrodes which are supplied in two feed channels (5) to a discharge nozzle (6) of the inner burner (1). The two electrodes are connected to two sliding contacts (4) for electrical energy transmission. According to the invention, the two sliding contacts (4) are displaceably mounted in the axial direction (10) and are each connected to a guide element (7) which is also displaceably mounted in the axial direction (10). The respective guide element (7) is axially pretensioned via at least one associated spring (11) and thereby presses the sliding contact (4) against the electrode, wherein the feed channels (5), the sliding contacts (4) and the guide elements (7) are arranged parallel to one another in the spraying head (2).

Abstract: A wire-like spray material (4) based on an iron for electric arc wire spraying and also a functional layer (2) which can be produced therewith on a substrate (1). The functional layer (2) has good corrosion resistance towards diesel fuel having a high sulphur content.

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: Piston pin for a connecting rod in a reciprocating internal combustion engine, wherein the piston pin carries at least in the area of the running surface a thermal sprayed slide layer of a metallic bearing material or slide bearing material, as well as reciprocating internal combustion engine with a connecting rod with small and with large connecting rod eye, wherein at least the running surface of one of the piston pins is formed of a thermal sprayed slide layer of a metallic bearing material, which exhibits a lower hardness than the running surface of the corresponding connecting rod eye and process for manufacturing a described piston pin with the steps of a extrusion molding or machining a piston pin preform, introduction of a recess in the area which will later become the running surface, roughening the outer surface in the area of the recess, application of a coating of a bearing material by a thermal spray process.

Abstract: The invention relates to an inner burner (1) for electric arc wire spraying of hollow spaces, particularly cylinder bearing surfaces (9), comprising two meltable electrodes which are supplied in two feed channels (5) to a discharge nozzle (6) of the inner burner (1). The two electrodes are connected to two sliding contacts (4) for electrical energy transmission. According to the invention, the two sliding contacts (4) are displaceably mounted in the axial direction (10) and are each connected to a guide element (7) which is also displaceably mounted in the axial direction (10). The respective guide element (7) is axially pretensioned via at least one associated spring (11) and thereby presses the sliding contact (4) against the electrode, wherein the feed channels (5), the sliding contacts (4) and the guide elements (7) are arranged parallel to one another in the spraying head (2).

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: The present invention relates to a process for applying a wear-resistant tribological coating to a sliding region of a synchronizer ring in which a thermally sprayed coating contains a maximum of approximately 40% by weight of solid lubricant, as well as to a synchronizer ring sliding region having a coating applied by such a process.

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: Piston pin for a connecting rod in a reciprocating internal combustion engine, wherein the piston pin carries at least in the area of the running surface a thermal sprayed slide layer of a metallic bearing material or slide bearing material, as well as reciprocating internal combustion engine with a connecting rod with small and with large connecting rod eye, wherein at least the running surface of one of the piston pins is formed of a thermal sprayed slide layer of a metallic bearing material, which exhibits a lower hardness than the running surface of the corresponding connecting rod eye and process for manufacturing a described piston pin with the steps of a extrusion molding or machining a piston pin preform, introduction of a recess in the area which will later become the running surface, roughening the outer surface in the area of the recess, application of a coating of a bearing material by a thermal spray process.

Abstract: The invention relates to a sliding surface (1), which is applied by arc spraying with the aid of a rotating tool. During the spraying process, the parameters are to be set in such a way that all the material particles are fused. The benefit of the high degree of fusion is that the sliding surface (1) can be machined by precision turning without the uncontrolled eruption of material. The rotating spraying process orientates the surface roughness on the face (1.2) of the sliding surface (1) transversally in the peripheral direction. This enables valley structures in the form of recesses (1.1) to be produced during the precision turning process, said recesses having a Peklenit factor of less than 1, achieving a high degree of flow obstruction and forming a defined oil-retaining volume.

Abstract: The present invention relates to a cylinder liner made from gray cast iron, an aluminum material or a ceramic material for an engine block for an internal combustion engine. According to the invention, it is provided that the cylinder liner has a thermally sprayed layer of a low-alloy iron alloy or a bonding layer, which consists of a nickel-aluminum alloy made up of 80 to 95% by weight of nickel and 5 to 20% by weight of aluminum, on its worn running surface, and has a layer serving as a tribological running surface on top of the bonding layer. The present invention also relates to a method for producing a cylinder liner of this type and to a composite part made up of an engine block for an internal combustion engine and at least one cylinder liner of this type. The invention allows the inexpensive repair of worn cylinder liners without the need to adapt new pistons.

Abstract: A method for surface treatment of the interiors of hollow bodies, especially cylinder bores, in preparation for the application of a thermally sprayed layer. The method comprises dry cutting without a lubricant or with a shortage of lubricant using a tool having a defined and/or undefined surface profile. In this method with a portion of the material forming the interior is removed and produces a surface that has a defined structure and/or quality. This eliminates the need for costly degreasing of the surface following machining.

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 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.