Valve train components having an oxidation and corrosion-resistant thermal spray coating

Abstract

Today's engines are pushed to operate at higher temperatures, higher peak cylinder pressures, in more corrosive environments and with highly variable fuel types and qualities. A solution to guttering is an oxidation and corrosion-resistant coating with a general turn MCrAlY applied to the face of the engine valve train components by thermal spray coating.

What is claimed is: 
     
       1. A method of making an engine valve train component for an internal combustion engine, comprising the steps of: grit blasting a face of the engine valve train component;   depositing an oxidation and corrosion-resistant coating material having the general form MCrAlY onto the face of the engine valve train component;   cooling the engine valve train component during the deposition;   grinding the face to finish dimensions.   
     
     
       2. The method of making an engine valve train component as set forth in claim 1, wherein the step of depositing includes depositing said coating material having about 17-31% by weight chromium. 
     
     
       3. The method of making an engine valve train as set forth in claim 1, wherein the step of depositing includes depositing said coating material having about 57-76% by weight nickel; about 17-31% by weight chromium; and the remainder aluminum, yttrium and trace elements. 
     
     
       4. The method of making an engine valve train component as set forth in claim 1, wherein said coating is a material generally being by weight about 16-32% Cr, 4-13% Al, 0-1% Y, 0-70% Fe, 0-77% Ni, 0-74% Co and trace elements. 
     
     
       5. The method of making an engine valve train component as set forth in claim 1, wherein the coating material generally being by weight about 31% Cr, 11% Al, 0.5% Y, and remainder nickel and trace elements. 
     
     
       6. A method of making an engine valve train component for an internal combustion engine, comprising the steps of: grit blasting a face of the engine valve train component;   depositing an oxidation and corrosion-resistant coating material onto the face of the engine valve train component to a thickness of about 0.015";   cooling the engine valve train component during the deposition; and   grinding the face to finish dimensions with about 0.010" coating thickness.   
     
     
       7. The method of making an engine valve train component according to claim 6, wherein said step of depositing an oxidation and corrosion-resistant coating material being depositing a material having a general form of MCrAlY. 
     
     
       8. The method of making an engine valve train component according to claim 6, wherein said step of depositing being depositing said coating material having about 17-31% by weight chromium. 
     
     
       9. The method of making an engine valve train component according to claim 6, wherein said step of depositing being depositing said coating material having about 57-76% by weight nickel; about 17-31% by weight chromium; and the remainder aluminum, yttrium and trace elements. 
     
     
       10. The method of making an engine valve train component according to claim 6, wherein said step of depositing said coating material having generally by weight about 17% Cr, 6% Al, 0.5% Y and remainder being Ni and trace elements. 
     
     
       11. The method of making an engine valve train component according to claim 6, wherein said step of depositing being depositing said coating material having generally by weight about 31% Cr, 11% Al, 0.5% Y, and remainder being Ni and trace elements. 
     
     
       12. The method of making an engine valve train component according to claim 6, wherein said depositing step includes applying the coating by a high velocity particle spray process. 
     
     
       13. The method of making an engine valve train component according to claim 12, wherein said high velocity particle spray process being a combustion process including mixing oxygen with a fuel gas stream, igniting said mixture, accelerating said mixture toward said face and injecting a powder of said coating material into said fuel gas stream. 
     
     
       14. The method of making an engine valve train component according to claim 13, wherein the step of injecting said powder includes injecting cermets into said fuel gas stream, said cermets becoming molten and being propelled toward said face. 
     
     
       15. The method of making an engine valve train component according to claim 13, wherein the step of accelerating being accelerating said mixture to a velocity of about 4500 feet per second. 
     
     
       16. The method of making an engine valve train component according to claim 13, wherein said powder having a particle size between about 11 μm and 44 μm. 
     
     
       17. An engine valve train component for an internal combustion engine comprising: a contact face; and   a coating being applied to said contact face, said coating being applied by a thermal spray process, said coating having general form MCrAlY.   
     
     
       18. The engine valve train component as set forth in claim 17, wherein said coating having a thickness of about 0.010". 
     
     
       19. The engine valve train component according to claim 17, wherein said coating having a composition by weight of about 17% Cr, 6% Al, 0.5% Y, and a remainder being Ni and trace elements. 
     
     
       20. The engine valve train component according to claim 17, wherein said coating having a composition by weight of about 31% Cr, 11% Al, 0.5% Y and a remainder being Ni and trace elements.