Method and apparatus for making a two piece unitary piston

• US 6,112,642 A
• Filed: 10/06/1998
• Issued: 09/05/2000
• Est. Priority Date: 10/06/1998
• Status: Expired due to Term

• Current Assignee: Caterpillar Incorporated
• Original Assignee: Caterpillar Incorporated
• Inventors: Weber, Robert L., Jarrett, Mark W., Koeslin, Werner H.
• Primary Examiner(s): Look, Edward K.
• Assistant Examiner(s): Lazo, Thomas E.
• Application Number:
  US09/168,396
• Time in Patent Office: 700 Days
• Field of Search: 92/186, 92/231, 92/260, 123/193.6, 123/193.4, 29/888.04, 29/888.042, 29/888.044
• US Class Current: 92/186
• CPC Class Codes: F02B 2275/14 Direct injection into combustion chamber
• CPC Class Codes: F02B 23/0621 Squish flow
• CPC Class Codes: F02B 23/0696 W-piston bowl, i.e. the combustion space having a central projection pointing towards the cylinder head and the surrounding wall being inclined towards the cylinder wall
• CPC Class Codes: F02B 3/06 with compression ignition compression ignition engines using air or gas for blowing fuel into compressed air in cylinder F02B13/02
• CPC Class Codes: F02F 2001/247 the valve stems being orientated in parallel with the cylinder axis
• CPC Class Codes: F02F 2200/04 Forging of engine parts
• CPC Class Codes: F02F 3/0015 Multi-part pistons
• CPC Class Codes: F05C 2201/021 Aluminium
• CPC Class Codes: F05C 2201/0448 Steel
• CPC Class Codes: Y02T 10/12 Improving ICE efficiencies
• CPC Class Codes: Y10T 29/49252 Multi-element piston making
• CPC Class Codes: Y10T 29/49256 with assembly or composite article making

Abstract

Past pistons have been susceptible to reduced longevity due to increased forces of combustion thereon during operating cycles of an engine. The present two piece unitary piston increases the longevity of pistons used with increased forces of combustion. For example, a head member has a crown portion defining a ring band portion having a bottom surface and a support portion. And, a skirt member defines a ring band support surface and a mating portion. The head member and the skirt member have a preestablished material strength being generally the same. The head member and the skirt member are joined at an interface of the support portion and the mating portion by an interference fit and are joined at the interface of the bottom surface and the ring band support surface by a weld. The force of combustion acting on the crown portion is resisted by the ring band support surface being in contacting relationship with the bottom surface. Thus, the skirt member structure supports and resists the bending moment of the combustion forces on the head member.

Claims

1. A two piece unitary piston being adapted for use with an engine, said two piece unitary piston comprising:

a head member being made of a material having a preestablished material strength, having a crown portion to which is connected a ring band portion defining a bottom surface, a support portion defining a support surface having a preestablished surface area, and an intermediate diameter having a preestablished value;

a skirt member being made of a material having a preestablished material strength being substantially the same as the preestablished material strength of said head member, having a ring band support surface being aligned with the bottom surface forming an interface, a mating portion defining a support surface being in contacting and supporting relationship with said support surface of said head member and an intermediate diameter having a preestablished value;

said intermediate diameter of said head member and said intermediate diameter of said skirt member forming an interference fit; and

said interface formed by said ring band support surface being aligned with said bottom surface being joined by a welding process.

2. The two piece unitary piston of claim 1 wherein each of said head member and said skirt member are made of steel.

3. The two piece unitary piston of claim 2 wherein each of said head member and said skirt member are formed as a forging.

4. The two piece unitary piston of claim 2 wherein said head member is formed as a forging and said skirt member is formed as a casting.

5. The two piece unitary piston of claim 2 wherein said head member is formed as a casting and said skirt member is formed as a forging.

6. The two piece unitary piston of claim 1 wherein said interface of said bottom surface and said ring band support surface being radially spaced from said interface of said support surface of said head member and said support surface of said skirt member.

7. The two piece unitary piston of claim 6 wherein said bottom surface and said ring band support surface being axially spaced from said interface of said support surface of said head member and said support surface of said skirt member.

8. The two piece unitary piston of claim 7 wherein said head member defining a combustion side and said interface of said support surface of said head member and said support surface of said skirt member being closer thereto than said interface of said bottom surface and ring band support surface (160).

9. The two piece unitary piston of claim 1 further comprising a piston cooling gallery.

10. The two piece unitary piston of claim 9 wherein said piston cooling gallery includes a head ring cooling gallery being positioned within said head member and a skirt member cooling gallery being positioned within said skirt member.

11. The two piece unitary piston of claim 9 wherein said piston cooling gallery includes a coolant inlet and a coolant outlet.

12. A method of making a two piece unitary piston, said method of making comprising the steps of:

forming a head member having a bottom surface and a support portion defining an intermediate diameter;

forming a skirt member having a ring band support surface and a support portion defining an intermediate diameter;

positioning said intermediate diameter of said head member in interference fitting relationship with said intermediate diameter of said skirt member;

positioning said support surface of said head member in contacting and supporting relationship with said support surface of said skirt member;

positioning said bottom surface in contacting relationship to said ring band support surface forming an interface; and

welding said interface of said bottom surface and said ring band support surface.

13. The method of making said two piece unitary piston of claim 12 wherein said step of forming said head member includes a forging operation.

14. The method of making said two piece unitary piston of claim 12 wherein said step of forming said skirt member includes a forging operation.

15. The method of making said two piece unitary piston of claim 12 wherein said step of forming said skirt member includes a casting.

16. The method of making said two piece unitary piston of claim 12 wherein said step of positioning said intermediate diameter of said head member in interference fitting relationship with said intermediate diameter of said skirt member includes a press fit.

17. The method of making said two piece unitary piston of claim 12 wherein said step of welding said interface of said bottom surface and said ring band support surface includes a diffusion bonding weld.

18. The method of making said two piece unitary piston of claim 12 wherein said step of welding said interface of said bottom surface and said ring band support surface includes an electron beam weld.

19. The method of making said two piece unitary piston of claim 12 wherein said step of welding said interface of said bottom surface and said ring band support surface includes a laser weld.

20. The method of making said two piece unitary piston of claim 12 wherein said step of positioning said support surface of said head member in contacting and supporting relationship with said support surface of said skirt member includes forcing said head member and skirt member together during said welding step.