阅读说明：本技术 一种活塞制作方法及活塞 (Piston manufacturing method and piston ) 是由 马飞 韩金峰 齐少豹 郭灵燕 于 2020-07-23 设计创作，主要内容包括：本发明属于机加工技术领域,公开了一种活塞制作方法及活塞。该活塞制作方法包括：采用磁控喷射方式,在活塞基体的顶面镀膜,形成金属层,金属层为氧化铝和氧化锆的复合金属层；采用微弧氧化方式,在金属层上进行电化学反应,形成陶瓷层,陶瓷层为孔洞状结构。该活塞制作方法,氧化铝和氧化锆的复合金属层在氧化锆的基础上增加了氧化铝,有效地降低金属层的热容,避免隔热存储大量的热导致燃烧室温度升高的情况,利于燃料的充分燃烧。同时,陶瓷层为疏松结构,其具有低热容的特性,进一步降低活塞基体的热容。另外,微观孔洞涂层中的空气导热系数极小,空气的导热性差,可阻碍高温燃气向活塞基体的热量传递,有效地降低活塞基体的热导率。(The invention belongs to the technical field of machining and discloses a piston manufacturing method and a piston. The manufacturing method of the piston comprises the following steps: coating a film on the top surface of the piston substrate by adopting a magnetic control spraying mode to form a metal layer, wherein the metal layer is a composite metal layer of aluminum oxide and zirconium oxide; and performing electrochemical reaction on the metal layer by adopting a micro-arc oxidation mode to form a ceramic layer, wherein the ceramic layer is in a hole-shaped structure. According to the piston manufacturing method, the aluminum oxide is added on the basis of the zirconium oxide in the composite metal layer of the aluminum oxide and the zirconium oxide, so that the heat capacity of the metal layer is effectively reduced, the condition that the temperature of a combustion chamber is increased due to heat insulation and storage of a large amount of heat is avoided, and the full combustion of fuel is facilitated. Meanwhile, the ceramic layer is of a loose structure and has the characteristic of low heat capacity, and the heat capacity of the piston base body is further reduced. In addition, the heat conductivity coefficient of air in the microscopic hole coating is extremely low, the heat conductivity of the air is poor, the heat transfer of high-temperature gas to the piston substrate can be blocked, and the heat conductivity of the piston substrate is effectively reduced.)

1. A method of making a piston, comprising:

coating a film on the top surface of a piston substrate (1) by adopting a magnetic control spraying mode to form a metal layer (2), wherein the metal layer (2) is a composite metal layer (2) of aluminum oxide and zirconium oxide;

and performing electrochemical reaction on the metal layer (2) by adopting a micro-arc oxidation mode to form a ceramic layer (3), wherein the ceramic layer (3) is in a hole-shaped structure.

2. The method of claim 1, wherein the magnetron spray pattern comprises the steps of:

filling inert gas in the vacuum chamber, and respectively arranging an aluminum target and a zirconium target in the vacuum chamber;

clamping the piston base body (1) by using a clamping assembly, controlling the top surface of the piston base body (1) to be away from the aluminum target and the zirconium target, and bombarding the surface of the aluminum target and the surface of the zirconium target by using incident ions generated by a low-pressure inert gas glow discharge reaction;

and clamping the piston base body (1) by using a clamping assembly and controlling the top surface of the piston base body (1) to be opposite to an aluminum target and a zirconium target, wherein aluminum atoms and zirconium atoms generated by sputtering the aluminum target and the zirconium target are sputtered and deposited on the top surface of the piston base body (1) to form a metal layer (2) with a thin film structure.

3. The method of manufacturing a piston according to claim 2, wherein the metal layer (2) is caused to form the ceramic layer (3) having zirconia in performing an electrochemical reaction by controlling a content ratio of the aluminum element and the zirconium element.

4. The method for manufacturing a piston according to claim 3, wherein the controlling of the content ratio of the aluminum element and the zirconium element is performed by adjusting sputtering angles of the aluminum target and the zirconium target, respectively, and controlling simultaneous sputtering of the aluminum target and the zirconium target.

5. The method of claim 2, wherein the pressure of the vacuum chamber before the inert gas is introduced is not more than 5 x 10^-4Pa, the pressure of the vacuum chamber after the inert gas is introduced is 0.1 Pa-0.9 Pa.

6. The method of claim 1, wherein the micro-arc oxidation comprises:

clamping the piston base body (1) by using a clamp assembly;

and electrically connecting the positive electrode of the pulse power supply to the piston base body (1), electrically connecting the negative electrode of the pulse power supply to the clamp assembly, placing the metal layer (2) on the top surface of the piston base body (1) in the electrolyte, and enabling the metal layer (2) to react with the electrolyte and perform micro-arc discharge on the surface of the metal layer (2) so as to form the ceramic layer (3) on the surface of the metal layer (2).

7. The method of claim 6, wherein the electrolyte is silicate electrolyte, the concentration of the electrolyte is 10g/L to 30g/L, the temperature of the electrolyte is not higher than 35 ℃, and the current density of the pulse power supply is 0.2A/dm²～0.4A/dm²The frequency of the pulse power supply is 50 Hz-500 Hz, the positive current duty ratio is 40% -50%, and the positive-negative current ratio of the pulse power supply is 0.7-1.3.

8. A method according to claim 1, characterized in that the piston base body (1) is pre-treated before the magnetron spraying.

9. The method of manufacturing a piston according to claim 8, wherein the pre-processing comprises the steps of:

grinding the top surface of the piston base body (1) by using sand paper to polish the piston base body to a mirror surface;

the piston matrix (1) is placed in an ultrasonic cleaning machine, and ultrasonic cleaning is carried out by using a cleaning agent;

the piston base body (1) is ultrasonically cleaned by deionized water and dried by hot air.

10. A piston manufactured by the method of manufacturing a piston according to any one of claims 1 to 9, the piston comprising:

a piston base body (1);

a metal layer (2) provided on the top surface of the piston base body (1);

a ceramic layer (3) disposed on a top surface of the metal layer (2).