Method for preparing a surface for applying a thermally sprayed layer

• US 8,752,256 B2
• Filed: 04/20/2009
• Issued: 06/17/2014
• Est. Priority Date: 04/21/2008
• Status: Active Grant

• Current Assignee: Ford Global Technologies, LLC (Ford Motor Company)
• Original Assignee: Ford Global Technologies, LLC (Ford Motor Company)
• Inventors: Verpoort, Clemens Maria, Silk, Mark Robert, Lindon, Spencer James
• Primary Examiner(s): Bryant, David
• Assistant Examiner(s): Hidalgo-Hernande, Ruth G
• Application Number:
  US12/935,671
• Publication Number:
  US 20110030663A1
• Time in Patent Office: 1,884 Days
• Field of Search: 29/810.2, 29/810.21, 29/811.2, 29/811.5, 29/901, 295/57, 29/900.1, 123/668, 72/40, 151/98, 152/361
• US Class Current: 29/90.01
• CPC Class Codes: A46B 2200/3093 Brush with abrasive properties, e.g. wire bristles
• CPC Class Codes: A46B 3/08 by clamping
• CPC Class Codes: A46B 7/06 movably during use , i.e. the normal brushing action causing movement driven brush bodies A46B13/00
• CPC Class Codes: A46B 7/10 as a rotating cylinder
• CPC Class Codes: A46B 9/02 Position or arrangement of bristles in relation to surface of the brush body, e.g. inclined, in rows, in groups
• CPC Class Codes: A46B 9/12 Non-adjustable supports
• CPC Class Codes: C23C 4/02 Pretreatment of the material to be coated, e.g. for coating on selected surface areas
• CPC Class Codes: Y10T 29/4506 for hollow workpiece
• CPC Class Codes: Y10T 29/47 Burnishing
• CPC Class Codes: Y10T 428/12208 Variation in both width and thickness

Abstract

A method for preparing a surface, previously roughed in a mechanical manner and comprising sharp-edged ridges and recesses, on metal workpieces for applying a thermally sprayed layer. The roughened layer is machined by hammer or percussion brushes with a rapidly rotating hammer or percussion brush having a plurality of resilient percussion wires that are oriented in a radially outward manner, such that the edges of the ridges are broken in order to improve the adhesion of the subsequently applied thermally sprayed layer or are at least curved forming rear sections. The brush rotates at a high rotational speed of approximately 3000-6000 rotations per minute and is displaced laterally with its rotational axis being at a parallel distance that remains constant in relation to the surface of the workpiece such that percussion wires distributed on the periphery of the brush impact with the ends thereof of the surface areas adjacent to the workpiece at an oblique angle that is less than 90° in rapid succession. The brush consists of an essentially cylindrical rotationally symmetrical brush body having a plurality of support bars that are parallel to the axis, that are mounted on the periphery of the brush between front-sided brush disks.

Claims

1. A process for preparing a surface of a cylindrical bore for application of a sprayed layer comprising:

forming a series of circumferentially-oriented alternating grooves and webs in the surface; and

operating a rotary brush to plastically deform the webs, the brush having a central shaft and at least one wire having a base end mounted for rotation about an axis parallel with and radially offset from the central shaft such that an entire length of the wire is rotatable about the axis, the wire having a length such that an outside diameter of the rotary brush is less than an inner diameter of the cylindrical bore, and operation of the brush comprising;

positioning the central shaft parallel with and offset from a central axis of the cylindrical bore;

rotating the brush about the central shaft such that the wire strikes a circumferential sector of the bore surface, is pulled along the sector, and then lifts off from the surface; and

moving the central axis in a circular pattern within the cylindrical bore to maintain a constant distance from the bore surface, such that the bore surface is contacted around its full circumference.

2. The process as claimed in claim 1, wherein the grooves have a trapezoidal to rectangular cross section.

3. The process as claimed in claim 1, wherein a diameter of the wires is greater than a groove width.

4. The process as claimed in claim 1, wherein a diameter of the wires corresponds to at least one times a groove spacing.

5. The process as claimed in claim 1, wherein a ratio of a groove depth to a groove width is between 0.2 and 1.

6. The process as claimed in claim 1, wherein a ratio of a groove spacing to a groove width is between 1.2 and 4.

7. The process as claimed in claim 1, wherein a groove spacing is between 0.1 mm and 1 mm.

8. The process as claimed in claim 1, wherein the brush comprises a plurality of axially parallel support bars arranged circumferentially with respect to the central shaft, each support bar rotatably supporting at least one wire.