Work procedure of the engine block

top surface with thermal spraying

Process

1 , Top surface damage removal (Previous processing)

2 , Insertion of masking for shot-blasting
3 , Shot-blasting , Removal of masking for shot-blasting
4 , Insertion of masking for thermal spraying
5 , Thermal spraying of Under-coat
6 , Thermal spraying of Top-coat
Removal of masking for thermal spraying
Inspection of the coating thickness

7 , Processing with the exclusive tool (CR-handle)

8 , Finish processing (In the case of 12V140-engine block)
9 , Finish processing (In the case of 6D140-engine block)
1 , Top surface damage removal (Previous processing)
12V140-engine block appearance
Processing surface to grind
Roughness : Less than 6.3s(Rmax)
1.All of the plugs remove
2.When there are the strain and the corrosion
of the engine block top surface, remove it in grinding
3.Measure the dimensions d between the crankshaft
center and the top surface (Cf. chart below)
4.Carry out the dimensions reconstruction
with thermal spraying in the case of dimensions
d<471.06mm
5.Setting of thermal spraying thickness
Calculating formula:471.5-d+0.4mm
Unit：mm
Basic dimensions Maximum permissible level
Dimension ｄ 471.5±0.04 471.06
 2 , Insertion of masking for shot-blasting
Appearance after masking completion for shot-blasting
~The photograph is 6D140-engine block~

The masking point

Adjust masking materials to push out
3.5mm - 4.0mm from the top surface.
Either putting the masking tape from the back side
or machined silicon rubber

Steel plate

Silicon rubber

Masking materials
Counter bore : Steel plate
(In the case of 140 engine block ;
Diameter 169.80±0.05mm , Thickness 15mm)
Other than a main bore : Silicon rubber of the taper Outer diameter=Counter bore diameter-0.4mm
Other than a bore : tape for masking Thickness=Counter bore depth+4.0mm
Besides thermal spraying part ： Use a cover (C0.5 chamfering)
(Even packing tape is possible)
Hole with the casting : Either putting masking tape
from the back side or machined silicon rubber
 3 , Shot-blasting , Removal of masking for shot-blasting
Use materials of shot-blasting
Appearance after shot-blasting Kind of materials : WA#24 (White Alumina)
Range of particle size : 24mesh(0.59mm)~8mesh(2mm)
(Manage the particle size by a sieve in shot-blasting device automatically)
Working hour : 5minutes/1face(An aim)
Instructions
1.A block not having adhesion for water and the oil
(So that materials cohere)
2.Do not let water and oil stick to the surface after shot-blasting.
Do not touch it barehanded
3.Because projection materials remain, remove masking
(as for the masking tape) of all points after shot-blasting,
and completely remove it by an air blow.
Materials
Roughness confirmation after shot-blasting
remainder
1.Confirm that there is not a varnish by viewing
(When shine is in the top surface, shot-blasting is insufficient)
2.Measure the surface more than five points with a portable surface
Appearance after the silicon
roughness measuring instrument, and confirm that
rubber removal Ra is more than 3.0 micron at all points
3.When Ra of more than 3.0 micron does not satisfy
even one place, carry out the shot-blasting again
Shot-blasting facility of KRI

~The photograph is 6D140 engine block~

 4 , Insertion of masking for thermal spraying

The masking point

Appearance after masking installation
for thermal spraying
~The photograph is 6D140 engine block~
A between the steel plate and the bore (Cf. chart below)
1.Adjust masking materials to push out 3.5mm - 4.0mm
from the top surface
2.Other than the top surface, apply either of masking tape
or cover or anti-bond application
3.The silicon rubber for thermal spraying may use it together
with shot-blasting
4.If anti-bond is applied, the steel plate for thermal spraying
may use it together with shot-blasting
(To restrain that coating adheres to a plate strongly)
5.Put masking tape on only the bottom to control the gap(0.2mm)
6.Start thermal spraying within 1 hour after shot-blasting

A Either putting the masking tape

The upper part at the time
of the thermal spraying
from the back side Steel plate
or machined silicon rubber

169.8±0.05mm
A gap 0.2mm
Either of
Steel plates masking tape or cover
Silicon rubbers or anti-bond application

Bottom at the time

Adjust a gap by masking tape of the thermal spraying

A-A section
 5 , Thermal spraying of Under-coat
Facilities appearance
(Arc thermal spraying)
Facilities specifications
A main body model : TUBE300 (A product made in Sulzer-Metco)
Current : 300A at the maximum
Voltage : 32V at the maximum
A spray gun model : Schub5 (A product made in Sulzer-Metco)

Use materials
Product : Sulzer-metco
Article name : Sulzer-metco8400_14
Arc thermal spraying appearance Wire diameter : 1.6mm
~The photograph is 6D140 engine block~ Weight : 25kg/roll
Composition : Ni5Al
1.Handle the thermal spraying conditions in a designated condition
(Cf. list shown below)
2.Letting robot overrun about 50mm for the engine block top surface dimensions
3.Before execution, adjust the scale of the electric current by a trial run
4.The engine block sets up a processing section perpendicularly for a floor,
put it so that counter bores form a line in the vertical direction
5.Remove all the masking jigs after thermal spraying and carry out cleaning
(To remove of the coatings which stuck to the side of the masking jigs)

Thermal spraying conditions list of Under-coat

Electrode Movement Speed Stand Air Pass number
Pitch Volume Current
(Wire) of Gun off Pressure of times
+ - [m/min] [mm] [mm] [bar] [V] [A] [Pass]
Ni5Al Ni5Al 45 5 150 3 26 200 2

Coating thickness : 170 micron (Average of 2 pass)

Because thickness with the thickness measuring instrument
Setting direction
is impossible of the measurement, manage it by a process
 6 , Thermal spraying of Top-coat, Removal of masking for thermal spraying,
Inspection of the coating thickness
Use materials
Product : Sulzer-metco
Article name : Metco Copper AW 14GA (Composition : Cu)
Metcoloy #3 14GA (Composition : 13Cr-Stainless)
Wire diameter : 1.6mm
Weight : 25kg/roll
1.Handle the thermal spraying conditions in a designated condition
Arc thermal spraying appearance (Cf. list shown below)
~The photograph is 6D140 engine block~ 2.Letting robot overrun about 50mm for the engine block top surface dimensions
3.Must not be able to pass in the mail in materials
(Set each materials to each electrode definitely)
4.Before execution, adjust the scale of the electric current by a trial run
5.Remove and clean the masking jigs inserted in bore every 2Pass
(To remove of the coatings which stuck to the side of the masking jigs)
6.Complete the cleaning of masking for oxidization prevention within 20 minutes
7.The engine block sets up a processing section perpendicularly for a floor, put
it so that counter bores form a line in the vertical direction
8.In the case of masking removal, you warn the coating not to be damaged
9.After thermal spraying, measure the coating thickness, and confirms
that the coating thickness is more than the necessary minimum thickness
10.Do not touch the surface directly while you measure
11.When the coating thickness does not satisfy even one place, carry out the
thermal spraying by addition once
Thermal spraying conditions list of Top-coat
Movement Stand Air Pass number of
Electrode (Wire) Pitch Volume Current
Speed of Gun off Pressure times
+ - [m/min] [mm] [mm] [bar] [V] [A] [Pass]
Set by necessary
Cu 13Cr-Stainless 18 5 150 3.0 32 200
thickness
Coating thickness : 250 micron (Average of 1 pass)
 7 , Processing with the special tool (CR-handle)
CR handle appearance
Shim insert point
(For height adjustment)
Screw for adjustment
(The outer diameter of the tool)
Fix after the diameter adjusted
Thing to use
1.CR-handle (Exclusive tool for deburring of the coating)
(Produce it every diameter of the bore)
2.Exclusive shim (It can use general-purpose) (1.0mm_1pieces , 0.5mm_4pieces)
Procedure
1.Adjust the tool of CR-handle by screw
(Formula:Counter bore diameter+0.6±0.1mm)
In the case of 140-engine, the tool adjusts to 170.8±0.1mm
(Counter bore diameter of 140-engine : 170.2mm)
Fix by locktite (adhesive) after the diameter adjusted
2.Insert CR-handle to counter bore in the condition
that inserted all exclusive shims (1.0mm-shim insert at the bottom)
3.Turn a lever by manual labor and deburring of the coating
(20 turns/shim : an aim)
4.Remove the coating while pulling 0.5mm-shim sequentially
5.Shim disappears when you repeat the above,
and operation completes if you remove the coating in this situation
6.When you extract CR-handle, warn that the coating not to be damaged
(After CR-handle extracted, check the coating by viewing)
7.After CR-handle extracted, measure inside diameter dimensions)
<A section schematic view at the time of the insertion>
Lever

Tool
Diameter : 170.8±0.1
（Model:140-engine）

Exclusive shim Positioning

<In the case of outer diameter is big>
You cannot insert CR-handle or quantity of processing becomes excessive
<In the case of outer diameter is small> The bore where you masked with
The tool of CR-handle does not touch the coating and cannot remove silicon rubber is good by no processing
 8 , Finish processing (In the case of 12V140-engine block)
Appearance of facility in KRI Appearance of tool

Material : CBN

1.The processing applies a list shown below condition

(Roughness, the plane degree assume it the rule
of the reman manual）
2.After processing, check the misses by viewing
3.After completion, check the dimensions
Pro cedure and c onditio n of finish proce ssing
(Quantity o f proc essing from th e most surfac e:0 .6mm)
Procedure V(m/min) V(rpm) f(mm/rev) f(mm/min) a(mm)
1 722 500 0.4 200 0.06
2 722 500 0.4 200 0.20
3 722 500 0.4 200 0.20
4 722 500 0.4 200 0.10
5 722 500 0.2 100 0.02
6 722 500 0.2 100 0.02
9 , Finish processing (In the case of 6D140-engine block)

Appearance of facility in KRI Appearance of tool

1.The 6D140 engine block is finished by grinding

(Roughness, the plane degree assume it the rule
of the reman manual）
2.After processing, check the misses by viewing
3.After completion, check the dimensions
 Work hour (Model : 12V140-engine block)

Insertion of masking for shot-blasting ----- 20 minutes

Shot-blasting ----- 10 minutes
Removal of masking for shot-blasting ----- 20 minutes
Insertion of masking for thermal spraying ----- 20 minutes
Set ----- 10 minutes
Thermal spraying of Under-coat ----- 13 minutes (Spray 8 minutes, Preparation 5 minutes)
Replacement of masking ----- 10 minutes (Preparation 5 minutes)
Thermal spraying of Top-coat (1) ----- 43 minutes (Spray 38 minutes, Preparation 5 minutes)
Replacement of masking ----- 10 minutes (Preparation 5 minutes)
Thermal spraying of Top-coat (2) ----- 43 minutes (Spray 38 minutes, Preparation 5 minutes)
Measurement of the coating thickness ----- 60 minutes
Removal of masking for thermal spraying ----- 20 minutes
Processing with CR-handle ----- 30 minutes
Finish processing ----- 80 minutes

Total ----- 389 minutes

The matter which has an influence on quality(Verboten)(1)
The matter which has an influence on quality(Verboten)(2)