Improve the reliability of basic components and ensure the operation of high performance internal combustion engines

As the first drafting unit of the recommended national standard “Technical Conditions for Reciprocating High-Power Internal Combustion Engines and Exhaust Valves”, Shanghai Gosstone Marine Fittings Co., Ltd. has gradually established a brand in the marine valve market with its excellent product quality. In the current severe market environment, it not only maintains a good development trend, but also orders are increasing. The general manager of the company, He Caitian, said in an interview with reporters that this is mainly due to the company's persistence in basic research, continuous improvement of process technology and product foundation, thus establishing a firm foothold in the market. He also pointed out that in order to meet the needs of large-scale, high-performance ships, the performance of marine diesel engines has been rapidly improved, but this improvement is not balanced, due to the lack of enthusiasm in the domestic industry to study and enhance the performance of the basic components of the ship. It has a certain impact on the stability and reliability of high performance marine machines.
With the increasing energy shortage and the growing problem of air pollution, the internal combustion engine manufacturing industry is facing a new round of innovation and change. On the one hand, diesel engines with a maximum burst pressure of 200 bar and an average effective pressure of 25 bar have become mainstream products on the market; on the other hand, the development of alternative fuels such as natural gas, shale gas and plant fuels And the application is becoming a major issue for the development of a large number of human and material resources by major internal combustion engine manufacturers and R&D institutions around the world.
As one of the key parts of the internal combustion engine, the operating environment of the gas valve is extremely harsh, and it faces various problems caused by high temperature, high pressure, exhaust gas corrosion, alternating stress and frequent impact. "The quality and reliability of the valve directly affect the operation of the internal combustion engine, and the improvement of various performance indexes of the internal combustion engine and the application of low-priced heavy oil and various combustible gases make the combustion exhaust temperature further improve, and the performance and manufacture of key components of the internal combustion engine are proposed. Higher requirements." He Caitian said that in response to these trends, Gossip has developed three patents of rolling hardening at room temperature, full-temperature deep rolling and high-temperature deep rolling after nearly 10 years of production practice. It can be applied to the manufacture of key components such as internal combustion engine valves. These technologies have achieved good results in the actual machine test certification, effectively reducing the carbon deposits in the combustion chamber components, and the various indicators have been greatly improved, laying a foundation for further improving the performance of the internal combustion engine.
Unlike conventional machining, rolling is a non-cutting technique. In recent years, many companies at home and abroad have been researching and developing rolling equipment and rolling tools that can adapt to various products, and have achieved certain results, especially in the inner hole rolling of small and medium-sized products and the outer surface of shaft products. In terms of rolling, professional manufacturing equipment and tools are available. However, it is understood that most of the rolling equipment and tools on the market cannot handle some relatively complicated workpiece surfaces. To this end, since 2001, Gossip has conducted targeted research and development. Since the gas valve damage mainly occurs on the sealing surface, if the sealing surface quality can be improved, it is not necessary to use expensive materials such as nickel-chromium superalloy. After repeated trials, in 2004, Gossstone designed and manufactured the first high-temperature rolling equipment for valve surface, which further improved the high temperature resistance, wear resistance, corrosion resistance and oxidation resistance of Sitali alloy. After high-temperature rolling, the metallographic structure of the surfacing alloy layer changes significantly, the metallographic structure of the material is more dense, the grain is refined, and the high-temperature thermal shock performance is greatly improved.
In 2004, Goldstone also signed a localization cooperation agreement with Hudong Heavy Machinery Co., Ltd. for the two-stroke diesel engine exhaust valve, and assumed the R&D, design and manufacturing tasks of rolling equipment. Four years later, the company randomly selected the parts and components produced by the equipment to be tested by the company. The results showed that the surface hardness of the products greatly exceeded the technical requirements of the company's "Vickers hardness (HV) of 540 ~ 580". One-time approval by MAN's new generation of Duraspindle exhaust valve qualified manufacturing suppliers. Moreover, the use of rolling hardening technology to produce exhaust valves not only reduces manufacturing costs by more than two-thirds, but also improves the product's high temperature, corrosion and wear resistance.
While breaking through the bottleneck of the key technology of the new generation of valve production, Gossstone has created a number of patented technologies such as the neck and bottom plane rolling of the valve. The surface of the valve with the temperature of the neck and the bottom plane is more dense. It is smoother and mirror-like, which improves the resistance to high temperature corrosion and carbon deposition, and also greatly improves the high temperature fatigue strength.
"In addition to air valves, rolling hardening technology can be well applied in the manufacture of cylinder liners, piston heads, crankshafts, connecting rods, etc." He Caitian believes that using rolling hardening technology without changing the raw materials It is one of the most economical and effective methods to change the metallographic structure of the surface of the part and improve the mechanical properties of the product, which can greatly extend the service life of the product. If this process can be further promoted and applied in the production process of internal combustion engine parts, it can greatly improve the anti-corrosion and anti-fatigue properties of components, and provide a strong guarantee for the operation of high-performance internal combustion engines.

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