DUPLEX POWDER METAL BEARING CAPS AND METHOD OF MAKING THEM

Abstract: A main bearing cap (A') made of powder metal has a body portion (Y) made from one powder metal material (Q), and a bearing arch portion (H), foot joint face portions (S) and/or wings (W) made of a different powder metal material (P). The material (Q) of the body portion (Y) is harder than the material (P) of the other portions (H, S, W), and the material (P) of the other portions (H, S, W) is relatively machinable. For the bearing arch portion (H), the machinability of the material (P) approximately matches the machinability of the bearing support structure (B) to which the bearing cap (A') is assembled to produce a good quality bore and longer tool life during line boring. The bearing arch material (P) may be a bearing material.

Description: DUPLEX POWDER METAL BEARING CAPS AND METHOD OF MAKING THEM BACKGROUND OF THE INVENTION FIELD OF THE INVENTION This invention relates to powder metal articles and their manufacture, and in paπicular to a main bearing cap in which the body is made of a high strength powder metal material and other parts are made with a different, more machinable powder metal material which is metallurgical^ bonded to the body. DISCUSSION OF THE PRIOR ART Fig. 1 illustrates a basic shape of a conventional main bearing cap (MBC). It is essentially a solid body with a semi-cylindrical recess and bolt holes for mounting. MBCs are used to retain the shell bearings and crankshaft of internal combustion engines. This is accomplished by bolting the MBC A (Fig. 2) to the lower end of the engine block B (Fig. 2). The semi-cylindrical recess C in the MBC corresponds to a similar semi- cylindrical recess D in the engine block so as to form a round hole when bolted together as shown in Fig. 3. In multiple cylinder engines, there are multiple MBC/cylinder block holes which are bored-out to a precise diameter E (Fig. 4) to accept bearing shells F (Fig. 5), which in turn locate and retain the crankshaft G (Fig. 5) in place. This boring operation is critical since the roundness and diametral precision have a significant effect on engine noise. A slightly oversize diameter allows the crankshaft to vibrate during operation. This is heard as a "rumble" that is unacceptable in modern passenger vehicles. A slightly undersize or out of round bore can cause binding of the crankshaft, preventing smooth low friction operation. Traditionally, the cylinder block has been made from either grey cast iron or an aluminum alloy, and the MBCs made from either grey cast iron or ductile cast iron (also called spheroidal or nodular cast iron). In recent years, a new material process combination has become commercially applied, namely a sintered powder metal (P/M) steel. A principal cost advantage of the P/M steel is the near net shape that can be achieved, which minimizes machining and associated costs of the product. However, since the MBC has to be bored at the same time as the cylinder block, there is a challenge related to the difference in machinability of the P/M steel and the block material (cast iron or aluminum alloy). This has lead to improvements in the P/M steel material machinability by well known and published means that include additions of machinability aids to the P/M material. This has been beneficial, but not universally successful in matching the MBC and block material machinability. A further issue is the ever increasing development of engine technology that continues to try to obtain more power from smaller (lower weight) and faster turning engines to extend fuel economy and performance respectively. A natural extension of the MBC technology to handle this added power-density and higher loads is to raise the strength of the P/M steel. This requires that the P/M steel be strengthened by some means, such as heat treatment, as is practiced in conventional steel technology. Heat treatment involves production of a stronger but also much harder steel which is difficult to bore, and results in very short lived and expensive cutting tooling. The short tool life means interrupted engine production on very costly automated machining lines. Thus, a need exists to match the machinability of the recesses C and D while maintaining a high strength, low weight beaπng cap of near net pre-machined shape and dimension. SUMMARY OF THE INVENTION The invention provides a two material beaπng cap made by powder metallurgy. In one aspect, there is a thin layer of a more machinable material lining the half circular bore of the bearing cap, with a stronger, harder material forming the majority and rest of the body of the bearing cap. In this aspect, a beaπng alloy composition may be used for the softer material in the bore arch region, which may be line bored to produce an integral beaπng surface, thereby eliminating the shell bearings which otherwise are used. The integral bearing bore is only possible in bearing caps used in aluminum engine blocks. Whether the more machinable powder material lining the half bore of the bearing cap is a bearing alloy or not, line boring is facilitated and tool life is prolonged by the invention.. Also in this aspect, the material lining the half circular bore of the beaπng cap is preferably chosen to match the machinability of the half circular bore of the engine block. In another aspect, there may be provided a two mateπal bearing cap made by powder metallurgy where there is a thin layer of a softer material on each joint face of the foot of the bearing cap, including where present, integral dowels, with a stronger harder material forming the majority and rest of the body of the bearing cap. By forming the dowels of a softer material, they are more conformable to the counterbore in the engine block in which they are pressed, and better repressed into them during the fit-up and installation of the crankshaft. In another aspect, the beaπng cap may be made with outboard wings for cross- bolting These wings may be made from a softer, more machinable mateπal, with a stronger, harder mateπal forming the majoπty and rest of the body of the beaπng cap Each of these aspects may be used alone, or m any combination with one or more of the other aspects These and other features and advantages of the invention will be apparent from the detailed descπption and drawings. BRIEF DESCRIPTION OF THE DRAWINGS Fig 1 is a perspective view of a pπor art mam beaπng cap; Fig 2 is a plan view illustrating how a main beaπng cap fits into an engine block, Fig 3 is a view like Fig 2, with the cap bolted to the block, Fig 4 is a view like Fig. 3, but after the beaπng bore has been bored out; Fig. 5 is a view like Fig 4, but with shell beaπngs F and crankshaft G installed; Fig 6 is a view like Fig 1, but of a main beaπng cap incorporating the invention; Fig. 7 is a view like Fig 2, but illustrating a main beaπng cap incorporating the invention pπor to line boπng, Fig 8 is a view like Fig 6, but after bolting and boπng, Fig. 9A is a sectional view of a die set-up, like Fig 12, with a bore lining powder being dispensed into the die cavity; Fig 9B is a detail view of a portion of Fig. 9 A, Fig. 10 illustrates the next stage of die filling m which the powder of the cap body is being dispensed into the die; Fig 11 illustrates the continuation of the filling step of Fig. 10, with the bore and leg punches lowered relative to the die housing; Fig 12 is a sectional view of a die model from the plane of the line 12-12 of Fie 13, Fig 13 is a top view of the die model of Fig. 12, Fig 14 is a sectional view of a die moQel from the plane ot the line 14-14 of Fig 13, Figs 15 A-H are views similar to Figs 9- 11 illustrating a die filling sequence for forming softer wings in a beaπng cap, and Fig 16 is a photomicrograph of the boundary of two mateπals made using the present invention DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT This invention offers a cost effective technical solution that could only be achieved by powder metallurgy The invention provides a localized area H (Figs 6 and 7) of machinable mateπal in the P/M steel MBC bore which is largely machined away to leave a thm layer I (Fig 8) In one aspect of the invention, this mateπal is introduced as a separate powder P (Fig 9), which is poured into the powder compaction die cavity ahead of the regular P/M steel powder Q that forms the bulk (or body) of the MBC A technical challenge is to localize the machinable powder P in the desired area An insufficient thickness of powder P matenal at any point would lead to the boπng tool hitting the harder P/M steel mateπal Q resulting in premature cutting tool failure An excess thickness of powder mateπal P results in loweπng the overall strength of the MBC since the residual P mateπal area is not as strong as the hardened powder Q mateπal However, the latter condition is prefeπed since the weakening effect will not be sigmficant provided the relative residual thickness of the softer weaker mateπal P is shallow compared to the bulk mateπal Q thickness It would be impossible to exactly match the thickness of P material to the depth of the material bored-out since there are inherent dimensional and locational variations in the boring process that result in different thicknesses being removed from MBC to MBC. A common thickness of mateπal bored-out from the MBC bore is 1mm (0.040 inches) with a variation from cap to cap of about 0.5mm (0.020 inches). In such a case, therefore, up to 1.25mm may be removed by boring. The thickness of material P prior to boring, i.e., the thickness of layer H in Fig. 7, may then be targeted to be a minimum of 2mm and a maximum of 4mm. This leaves up to 2mm thickness of material P after boring, i.e., the thickness of layer I, which compares with typically a minimum of 50mm of material Q thickness. Thus, the relative thickness of soft material P to hard, strong material Q is only 4%. The strength reduction would therefore be 4% of the difference in strength between the two materials. This is not a functionally significant reduction in strength. To locate the powder P in the correct location, a press is used in which the individual compaction tooling members have independent motion control, and is preferably a fully computer controlled compaction press. Also, a dual powder handling system is needed to keep the two powders separate until they are in the compaction die cavity, and also to deliver powder P in the correct location and to the coπect depth, suπounded by powder Q. Compaction tooling design and dual powder filling were initially researched by use of a clear plastic die model which simulated the production compaction tooling, and where two different colored powders were used to track the initial, transient and final location of the two powders during the powder filling steps and subsequent pre- positioning of the tooling elements for compaction. Figs. 12-14 show the clear plastic simulated compaction tooling 10. Fig. 13 shows in dashed lines the powder P filling shoe 12 and the powder Q filling shoe 14 in dotted lines. The shoes 12, 14 in their simplest form are open bottom boxes which contain the powder P to be charged into the cavity in die 1 1. The shoes 12, 14 are moved back and forth over the die cavity in the axial direction indicated by arrow 16. This is the axial direction relative to the bearing cap bore C. In the die cavity are positioned two leg punches 20 and an arch punch 22 between them. The leg punches 20 are movable up and down together. The arch punch 22 is also movable up and down, but independently of the leg punches 20. Not illustrated in Figs. 9A-14 are core rods which would be used for forming the bolt bores through the legs of the bearing cap, although in a production bearing cap those bores would be formed by such core rods. Figures 9A and 9B show the filling of the first powder P, which is relatively machinable powder, into a die set like that shown in Figs. 12-14. Figs. 10 and 1 1 show the distributions of powders P and Q during powder charging and after powder Q has been charged into the die cavity and the tooling elements moved to their final position, prior to the powder compaction stage. It can be seen that the powder P forms a fairly uniform layer around the bore area. This was the result of finding the optimum initial powder filling pattern and mechanism which results in the desired pre-compaction pattern shown in Fig. 11. This is achieved by positioning the tool elements as shown in Fig. 9 and by using a powder P filling shoe 12 of a specific width. This is shown in Fig. 9, where powder P forms a shaped profile in cross-section, viewed in the axial direction, which is a flat topped triangular shape. This shape is dictated by the "angle of repose" of the powder P. This is the natural angle formed when the powder is poured in a naπow stream to form a cone shaped pile. Using this approach, the width of the feed shoe 12 for powder P is adjusted to form the ideal initial pattern. Then a full width feed shoe containing powder Q is passed over the die cavity such that powder Q falls on top of powder P, filling in the spaces left by the slopes of powder P. Next, the tool elements (the three punches 20 and 22) are moved to their pre-compaction position. It is during this motion that the shape of powder P changes to the ideal shape for subsequent compaction. Unfortunately, the two colored powders cannot be compacted in the plastic tooling since the plastic would crack under the pressure needed. Therefore, the lessons learned from this stage of development were taken and applied to actual production tooling which is made from high strength tool steels (the punches 20, 22) and tungsten carbide (the die 11). Using the pre-set tool element positions, samples were made from two powders P and Q as described earlier. After compaction and sintering, the final shape of the two compacted powders P and Q was examined by sectioning the compact and observing the boundary as shown (lOOx magnification Nital Etch) in the photomicrograph of Fig. 16. The result was that a layer of approximately 2mm to 4mm was formed around the bore section, which was the intent of the invention. Repeated trials resulted in sample compacts of MBCs which were sintered (the thermal process that metallurgically bonds the powder particles together) and the resulting MBCs examined for microstructure integrity at the bond zone between the powders P and Q. This was found to be excellent. In a variation of the invention, the first material P is also located on the joint faces of the legs of the MBC. This is illustrated in Figs. 15 A-H, in which the voids R are filled with the softer powder metal P. to form tapered bosses S (Fig. 15H, also referred to as integral hollow dowels). The tapered bosses S are molded onto the surface of each cap foot as disclosed m commonly owned International Patent Publication No WO 97/42424, which is hereby incorporated by reference, to locate in a counterbore T (Fig 2) on the mating bulkhead Where the main body Y (Fig 15H) of the MBC needs to be high strength/high hardness, a repressing step to calibrate the diametral size and angle of the integral dowel may be impractical if the dowel is the same mateπal as the body This is because strong hard P/M steel will not plastically yield to form the ideal geometry, but will either spπng back to the oπgmal shape, crack due to bπttleness, or crack the repressing tool Therefore, a layer of softer P/M mateπal which includes the integral dowels, formed according to the present invention, enables the repressing process to be realized Since this region of the MBC is in compression in service due to bolt loading, there is no detπment to the functional strength of the MBC. In a third example of the invention, the MBC design includes extended wings W (Fig 2) that are bolted by bolts X (Fig 3) hoπzontally to the cylinder block to provide πgidity and quietness This design is called "cross bolted" and is gaimng in populaπty Unfortunately, the design demands that the mateπal of the wmgs be machinable to accept a tapped hole which receives the bolt threads Strong hard P/M steel with a bainite or martensite structure is extremely difficult to dπll and tap. Dπll-bit life and tap life would be uneconomical. To overcome this problem, the invention proposes to make the wmgs W from the softer machinable powder mateπal P Figure 15A shows the initial tool set position ready to receive the soft powder P The tool set includes bore punch 22, leg punches 20', core rods 21 mside the leg punches 20', and wing punches 23 , all inside die 11'. Fιg. l5B shows the powder P filling device 12', which is essentially an inverted open bottom box containing powder P over the tool set. Figure 15C shows the condition after the powder fill box is withdrawn, thereby strickling (scraping excess powder off) the surface. Figure 15D shows the second powder fill box 14' containing powder Q over the tool set. Figure 15E shows the tooling moved to the final filling position, which draws powder Q into the tool set. Figure 15F shows the condition where the second powder fill box 14' has withdrawn and strickled off the surface. The upper punch is also shown in Fig. 15G, ready to advance and compact the powders. Figure 15G shows the compaction completion, with upper punch 29 compacting the powders in the die 11 ', and Figure 15H shows the dual material compact A' after ejection from the tooling, with softer half bore H, softer bosses S and softer wings W. In a fourth application of the invention, the machinable material P would be made from a powder metal bearing material. In this case, it would be possible to dispense with the traditional shell bearings, and use the bearing cap bore layer material as the bearing surface for the crankshaft. In this instance, the mating surface of the cylinder block would be the other half of the bearing. Since the cylinder block half of the bearing has much lower loads to bear (the combustion stroke is directed away from this surface), then the parent block material would be adequate for at least low to medium duty engines. There is a significant cost savings in eliminating these half shell bearings. The main bearing cap compact A' is, of course, sintered to bind the powder particles together. Any suitable sintering process may be used. The result is the finished or near finished main bearing cap A', with the powder metal distributions as illustrated in Fig. 15H. The bearing cap A' is finished at this point unless some subsequent resizing, heat treating or surface finishing operations are needed to finish it. In any of these constructions, the body Y material Q may be partially or fully hardened during or after sintering to a bainitic and or martensitic microstructure, but the soft mateπal P is chosen such that it does not respond to the hardening process, remaining soft and machinable. For the particular mateπals to make a beaπng cap of the invention, the softer, more machinable powder mateπal P may be a low to medium carbon powder metal steel (e.g., O - 0.7%) carbon) containing a machinability aid including but not restπcted to one or more of copper above 3%>, manganese sulfide up to 1%, boron nitπde (non-cubic) up to 0.2%), magnesium silicate up to 1 %>, and calcium fluonde up to 1 % The harder body mateπal Q may be a 0.45-0.65%) carbon, 0.45-0.65%) phosphorus. 2-4% copper powder metal steel, or a 0.3-0.7%. carbon, 0.3 % copper steel. Many modifications and vaπations to the preferred embodiments descπbed will be apparent to those skilled m the art Therefore, the invention should not be limited to the embodiments descπbed, but should be defined by the claims which follow.

Claims: We claim: 1. In a bearing cap of the type which is bolted to a bearing support structure so as to define a bearing bore between a bore arch of said cap and said structure and in which bolt holes for securing said cap to said structure extend through feet of said cap and into said structure, said cap having at least two of said feet, one said foot on each side of said bore arch with at least one bolt hole extending through each said foot, the improvement wherein: said cap is made from two different sintered powder metal materials. 2. The improvement of claim 1 , wherein one of said powder metal materials is softer than the other. 3. The improvement of claim 2, wherein the softer powder metal material is positioned adjacent to said bore arch. 4. The improvement of claim 3, wherein the machinability of said softer powder metal material approximately matches the machinability of said bearing support structure adjacent to said bore. 5. The improvement of claim 3, wherein said softer powder metal material is also positioned on joint faces of said feet. 6. The improvement of claim 5, wherein integral dowels are formed on said joint faces of said feet, and said integral dowels are made of said softer powder metal material. 7. The improvement of claim 1, wherein wings extend from ends of said bearing cap, and said wings are formed from said softer powder metal material. 8. The improvement of claim 7, wherein said softer powder metal material is also positioned on joint faces of said feet. 9. The improvement of claim 8, wherein integral dowels are formed on said joint faces of said feet, and said integral dowels are made of said softer powder metal material. 10. The improvement of claim 1 , wherein one of said powder metal materials is softer than the other, and said softer material is a low to medium carbon powder metal steel having 0-0.7%> carbon and contains a machinability aid. 11. The improvement of claim 10, wherein said machinability aid is one or more materials selected from the group consisting of: copper above 3%>; manganese sulfide up to 1%>; non-cubic boron nitride up to 0.2%>; magnesium silicate up to 1%>; and calcium fluoride up to 1%. 12. The improvement of claim 1 , wherein one of said powder metal materials is harder than the other, and said harder material is selected from the group consisting of: a powder metal steel containing 0.45-0.65%) carbon, 0.45-0.65%) phosphorus and 2-4%> copper; and.a powder metal steel containing 0.3-0.7%o carbon and 0-3% copper. 13. The improvement of claim 1, wherein one of said materials is hardened and the other material remains soft. 14. The improvement of claim 13, wherein said hardened material is hardened to a bainitic microstructure. 15. The improvement of claim 13 wherein said hardened material is hardened to a martensitic microstructure. 16. The improvement of claim 1, wherein said two materials differ in hardness, a body of said bearing cap is made of the harder one of said materials and an exposed surface of said bearing cap is made of the softer one of said materials. 17. The improvement of claim 16, wherein said surface made of the softer powder metal material is a bore arch of said bearing cap. 18. The improvement of claim 17, wherein said softer powder metal material is also positioned on joint faces of said feet. 19. The improvement of claim 18, wherein integral dowels are formed on said joint faces of said feet, and said integral dowels are made of said softer powder metal material. 20. The improvement of claim 19, wherein wings extend from ends of said bearing cap, and said wings are formed from said softer powder metal material.

Inventors: CADLE TERRY M, MANDEL JOEL H, CADLE, TERRY, M., MANDEL, JOEL, H.
Applicants: CADLE TERRY M, GKN SINTER METALS GERMANTOWN I, MANDEL JOEL H, CADLE, TERRY, M., GKN SINTER METALS-GERMANTOWN, INC., MANDEL, JOEL, H.
Application year: 2000
Main classification: F16C17
IPC codes: F16C9, F16C17, F16C33