Abstract：Decreasing the weight of engine is an important method for lightweight of automobile.Traditional method is that cast iron sleeve is inlayed in cylindrical bores and aluminum alloy is used for outer covering of engine.This method not only have some defects such as cast iron without mosaic firmly and wear with outer cover of engine,but also the weight of engine is still massive.
With the technology of electric arc spraying cylindrical bores invented,the tradition method of inlaying cast iron liner into aluminum alloy engine has been improved deeply.The volume and weight of engine have been decrensed so much.This method is not only excellent but also economic method.In recent years electric arc spraying cylindrical bores has been developed quickly.The equipments of the technique are also produced.By using this technique, automobile`lightweight is fulfilled efficiently,and it is a trend which is mechanizion process of modern spraying equipment.
In this paper,in basis of reform to traditional electric arc spraying equipment,we design an electric arc spraying cylindrical bores apparatus with the technology of unifilar tungsten. Traditonal design of twin-wire is difficult to fulfill the request.If change the direction of spraying,it is necessary to make wire bended so that increasing the resistance of wire feeding.Wire feeding roughly has to affect coat’s quality.With equipment of unifilar tungsten,tungsten and wire have an 90°angle.High pressure gas blow around tungsten.In this way,it can not only fufill the request about direction of sparying cylindrical ,but also wire feeding in straight line.Resistance has alson decrease.With single-wire feeding,the space of apparatus of wire feeding can decrease and it is easy to fix tungsten.The volume of whole apparatus can decrease deeply.
The apparatus is applied in the above 80mm aluminum engine inner’s spraying. The dimensional drawings and assembly drawings are done by using AutoCAD,and then using SolidWorks to do 3D effect diagram.It is to make some modifications of design by using 3D effect diagram before machining.The apparatus is made up of 2 main parts which is the structure of wire-feeding and spraying.In this research have produced two kinds of electric arc spraying cylindrical bores.Although the original apparatus can make the coat which fulfill requirements,it is very difficult to apply to cylindrical bore of small size due to large volume.Through optimization to original apparatus,we have designed and produced a new apparatus with smaller size.Last we practise to make a cylindrical bore coat and do a series of tests.Test data shows that the coat with optimized apparatus is fulfill the requests of sparying cylindrical bores.
Keywords: lightweight of automobile, electric arc spraying, spraying cylindrical bore,unifilar tungsten
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