Molibden kaplı piston segmanlarının aşınma davranışlarının incelenmesi ve optimizasyonu

02/ø%'(1.$3/,3ø67216(*0$1/$5,1,1

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(QVWLW$QDELOLP'DOÕ : 0$.ø1$(öø7ø0ø

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g16g= ... ii

ødø1'(.ø/(5 ... iii

6ø0*(/(59(.,6$/70$/$5/ø67(6ø ... vi

ù(.ø//(5/ø67(6ø ... ix

TABLOLAR /ø67(6ø ... xi

g=(7« ... xii

SUMMARY ... xiii

%g/h0.1. *ø5øù.. ... 1

%g/h0 2. 6h57h10(- $ù,10$- <$ö/$0$ ... 4

2.1. 6UWQPH ... 4

2.1.1. 6UWQPHoHúLWOHUL ... 7

2.1.1.1. .XUXVUWQPH ... 7

6ÕYÕVUWQPH ... 7

2.1.1.3. 6ÕQÕUVUWQPH ... 8

2.2. $úÕQPD ... 8

2.2.1. $úÕQPDoHúLWOHUL ... 12

2.2.1.1. $GKHVLIDúÕQPD ... 14

2.2.1.2. $EUDVLIDúÕQPD ... 17

2.2.1.3. (URVLIDúÕQPD ... 21

2.2.1.4. )UHWWLQJDúÕQPD ... 24

2.2.1.5. .RUR]LIDúÕQPD ... 26

2.2.1.6. <RUXOPDDúÕQPD ... 28

iv

2.3. <D÷ODPD ... 29

2.3.1. <D÷ODPDUHMLPOHUL ... 31

2.3.1.1. +LGURGLQDPLN\D÷ODPD ... 31

2.3.1.2. Elastohidrodinamik yD÷ODPD ... 33

2.3.1.3. .DUÕúÕN\D÷ODPD ... 33

2.3.1.4. 6ÕQÕU\D÷ODPD ... 34

2.4. .DWÕ<D÷OD\ÕFÕODU ... 35

2.4.1. Molibden ... 35

%g/h0.3. SEGMANLAR VE 75ø%2/2-ø6ø ... 37

3.1. Segman Malzemeleri ... 38

3.2. 6HJPDQdHúLWOHUL ... 39

3.3. Segman Tribolojisi ... 40

3.4. 6HJPDQ.DSODPDODUÕ ... 42

%g/h0.4. MATERYAL VE METOD ... 45

4.1. Materyal ... 45

4.2. .DSODPD<|QWHPL... 46

4.2.1. HVOF Kaplama Sistemleri ... 46

4.2.2. HVOF sisteminin uygulama prensibi ... 47

4.3. 0HWDORJUDILNøQFHOHPHOHU ... 47

4.4. 7DUDPDOÕ(OHNWURQ0LNURVNRSX6(0$QDOL]OHUL ... 48

4.5. 6HUWOLNgOoPOHUL ... 48

<R÷XQOXNgOoPOHUL ... 48

4.7. 7DJXFKL'HQHH\VHO2SWLPL]DV\RQ<|QWHPL ... 49

4.7.1. 6LQ\DO*UOWRUDQÕ ... 50

4.7.2. Ortogonal dizilier... 51

4.7.3. )DNW|UOHULQHWNLOHúLPL ... 53

4.7.4. Varyans analizi (ANOVA)... 54

4.7.4.1. 7RSODPNDUHOHUWRSODPÕ ... 54

4.7.4.2. Serbestlik derecesi... 55

v

4.7.4.3. Varyans ... 55

4.7.4.4. F testi ... 56

4.7.4.5. 6RQXFX\]GHNDWNÕ3 ... 56

4.7.5. 'R÷UXODPDGHQH\OHUL ... 56

4.7.6. Regresyon analizi ... 57

4.8. 6UWQPH9H$úÕQPD'HQH\OHUL ... 58

%g/h0.5. 6218d/$59('(ö(5/(1'ø50( ... 60

5.1. 0ROLEGHQ7R]XQXQg]HOOLNOHULQLQøQFHOHQPHVL ... 61

5.2. Metalografik Analizler... 63

5.3. 6HUWOLN9H<R÷XQOXNgOoPOHUL ... 64

5.4. .RQWURO)DNW|UOHULQLQ(WNLVL ... 65

5.5. Anova ... 68

5.6. Regresyon Analizi ... 70

5.7. 'R÷UXODPD'HQH\OHUL ... 70

5.8. $úÕQPD+DULWDODUÕ ... 72

5.9. $úÕQPD0HNDQL]PDODUÕ ... 75

%g/h0.6. GENEL 6218d/$59(g1(5ø/(5 ... 77

KAYNAKLAR ... 79

g=*(d0øù ... 84

vi

6ø0*(/(59(.,6$/70$/$5/ø67(6ø

Al : $OPLQ\XP

C : Karbon

Co : Kobalt

Cr : Krom

Cu : %DNÕU

CH4 : Metan

C2H4 : Etilen

C3H6 : Propilen

C3H8 : Propan

CrO3 : Kromik asit İ

F

: :

Hata

Fren terazi kuvveti

Fe : Demir

Fn : Normal kuvvet

Fs : 6UWQPHNXYYHWL

H₂ : Hidrojen

H2SO4 : 6OILULNDVLW

L(y) : +HGHIGH÷HUGHQVDSPD

l : Yol, m

m : +HGHIGH÷HU

Mg : Magnezyum

Mn : Mangan

mKuru : .XUXD÷ÕUOÕN m_<Dú

N

: :

<DúD÷ÕUOÕN

*|]OHPOHULQWRSODPVD\ÕVÕ

Ni : Nikel

n : Motor devri, devir/dakika

vii N_e

O2

: :

(WNLQWHNUDUODPDVD\ÕVÕ Oksijen

P : %DVÕQoEDU

ppm : 0LO\RQGDELUSDUWLNO PVD : Fiziksel buhar biriktirme

Pe : (IHNWLIJoN:

R² : RHJUHV\RQNDWVD\ÕVÕ

Si : Silisyum

SOx : .NUWoksitler

T : 7PJ|]OHPOHULQWRSODPÕ

Ti : Titanyum

V : Hacim, cm³

Vh : Strok hacmi, m³

DOF_A : $IDNW|UQQVHUEHVWOLNGHUHFHVL DOF_B : %IDNW|UQQVHUEHVWOLNGHUHFHVL DOF_T : Toplam serbestlik derecesi Vp : 3LVWRQKÕ]ÕPV

: 2UWDODPDSLVWRQKÕ]Õ (m/s)

W : Tungsten

WC : 7XQJVWHQNDUEU

Wo : $úÕQPDRUDQÕ

Z : dHYULPEDúÕQDGHYLUVD\ÕVÕ

U _: <R÷XQOXN

— : 6UWQPHNDWVD\ÕVÕ

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Kv ^: 9ROPHWULNYHULP

V Ve

'V

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7NHWLOHQ\DNÕWKDFPL ANOVA

$g1

: :

Varyans analizi tablosu

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APS : Atmosferik plazma sprey

viii CVD : Kimyasal buhar biriktirme

DC : 'R÷UXDNÕP

DIN : Alman normu

DOF E EHD

: : :

Serbestlik derecesi

<RXQJPRGO

Elastohidrodinamik FMEP : 2UWDODPDVUWQPHEDVÕQFÕ G

GIMEP

: :

*UOW

%UWRUWDODPDLQGLNHEDVÕQo H

HV HVOF

: : :

Sertlik

Vickers sertlik

<NVHNKÕ]OÕDOHYSVNUWPH HFK : +DYDID]ODOÕNNDWVD\ÕVÕ H/Y : Hava-\DNÕWRUDQÕ

MMK MoO₃

: :

Metal matrisli kompozit Molibden trioksit

Mo : Molibden

PTFE S

: :

Poly tetra flor etilen .NUW

SDQ_T : KDUHOHUWRSODPÕ

SSAXB : $YH%IDNW|UOHULQLQHWNLOHúLPIDNW|UQHDLWNDUHOHUWRSODPÕ SSe : +DWDNDUHOHUWRSODPÕ

hg1 : hVW|OQRNWD

VI : 6DQDOHQVWUPDQ

Zn : dLQNR

ix

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ùHNLO.1. 6UWQPH(VQDVÕQGDNL*HUoHN7HPDV1RNWDODUÕ ... 5

ùHNLO2.2. 6WDWLNVUWQPHNDWVD\ÕVÕQÕQkontak VUHVL\OHGH÷LúLPL ve kinetik sUWQPHNDWVD\ÕVÕVQÕQND\PDKÕ]Õ\ODGH÷LúLPL ... 6

ùHNLO <]H\OHULQ mekanik ve PROHNOHUHWNLOHúLPL ... 12

ùHNLO. $EUDVLIDúÕQPDQÕQDúDPDODUÕ ... 15

ùHNLO. $GKH]\RQGDQGROD\ÕPDO]HPHWUDQVIHUL ... 16

ùHNLO. øNLYHoHOHPDQOÕDEUDV\RQPHNDQL]PDVÕ ... 18

ùHNLO. .DWÕELU\]H\LOHNRQLNDEUDVLISDUWLNOQWHPDVÕ ... 19

ùHNLO. øNLIDUNOÕDEUDVLIDúÕQPDPRGXD ploughing modu b) kesme modu . 20

ùHNLO. (UR]LIDúÕQPDGDROXúDELOHFHNPXKWHPHODúÕQPDPHNDQL]PDODUÕ ... 22

ùHNLO.10. (UR]LIDúÕQPDGDSDUWLNOoDUSPDKÕ]ÕYHDoÕVÕQÕQúHPDWLNJ|VWHULPL. 23

ùHNLO.2.11. Gevrek-VQHNPDO]HPHGHHUR]LIDúÕQPD\DoDUSPDDoÕVÕQÕQ etkisi... 24

ùHNLO ']]HPLQHGR÷UXEDVWÕUÕOPÕú NUHQLQDOWÕQGDNL elastik gerilim GD÷ÕOÕPÕ ... 25

ùHNLO 6HJPDQÕQNÕVÕPODUÕ ... 37

ùHNLO.3.2. .RPSUHV\RQYH\D÷VHJPDQODUÕQÕQSLVWRQGDNL\HUOHULQLQJ|VWHULOLúL 39

ùHNLO.1. +92)oDOÕúPDSUHQVLEL ... 47

ùHNLO. 7DJXFKLGHQH\WDVDUÕPÕQGDNLLúOHPVÕUDVÕ ... 49

ùHNLO. /RUWRJRQDOGL]LQHDLWOLQHHUHWNLOHúLPJUDIL÷L ... 53

ùHNLO. Molibden kaplama tozuna ait 6(0J|UQWV ... 62

ùHNLO.2. 0ROLEGHQWR]XQXQ6(0J|UQúYH(';DQDOL]L ... 62

ùHNLO. 0ROLEGHQNDSODPDQÕQ6(0J|UQWV ... 63

ùHNLO. 0ROLEGHQNDSOÕNÕUÕNVHJPDQ\]H\L6(0J|UQWV ... 64

ùHNLO5. 0ROLEGHQNDSOÕVHJPDQÕQ6(0J|UQWVYH(';DQDOL]L ... 64

ùHNLO6. 6HJPDQDúÕQPDND\EÕLoLQ61JUDIL÷L ... 66

ùHNLO7. 6HJPDQDúÕQPDND\EÕLoLQ61HWNLOHúLPJUDIL÷L ... 67

x

ùHNLO8. *|POHNDúÕQPDND\EÕLoLQ61JUDIL÷L ... 67

ùHNLO9. *|POHNDúÕQPDND\EÕLoLQ61HWNLOHúLPJUDIL÷L ... 68

ùHNLO10. 6ÕFDNOÕNYH\NGH÷LúLPLQHJ|UHVHJPDQDúÕQPDKDULWDVÕ ... 72

ùHNLO.11. 'HYLUYHVÕFDNOÕNGH÷LúLPLQHJ|UHVHJPDQDúÕQPDKDULWDVÕ ... 73

ùHNLO12. 6ÕFDNOÕNYH\NGH÷LúLPLQHJ|UHJ|POHNDúÕQPDKDULWDVÕ ... 73

ùHNLO13. 'HYLUYHVÕFDNOÕNGH÷LúLPLQHJ|UHJ|POHNDúÕQPDKDULWDVÕ ... 74

ùHNLO '|NPHGHPLU1\NDOWÕQGDDb) 80 c) 120 dev/dak kayma KÕ]ÕúDUWODUÕQDDLWDúÕQPDPHNDQL]PDODUÕ ... 75

xi

TABLOLAR /ø67(6ø

Tablo 4.1. GG 20-30 G|NPHGHPLUVHJPDQÕQNLP\DVDOELOHúHQOHUL ... 45

Tablo 4.2. GG 20-G|NPHGHPLUVLOLQGLUJ|POH÷LQLQNLP\DVDOELOHúHQOHUL .... 45

Tablo 4.3. HVOF kaplama parametreleri ... 46

Tablo 4.4. 2UWRJRQDO/GL]LQLQLQJ|VWHULPL ... 52

Tablo 4.5. 7DJXFKLRSWLPL]DV\RQPHWRGXQDJ|UHGHQH\VHOúDUWODU ... 59

Tablo 5.1. .RQWUROIDNW|UOHULYHVHYL\HOHUL ... 60

Tablo 5.2. /7DJXFKLRUWRJRQDOGL]LVLQHJ|UHGHQH\VHOYH61VRQXoODUÕ ... 61

Tablo 5.3. 6HJPDQYHJ|POHNOHULQ\R÷XQOXNYHVHUWOLNGH÷HUOHUL ... 65

Tablo 5.4. SegmDQD÷ÕUOÕNND\EÕLoLQ61FHYDSWDEORVX ... 65

Tablo 5.5. *|POHND÷ÕUOÕNND\EÕLoLQ61FHYDSWDEORVX ... 65

Tablo 5.6. 6HJPDQLoLQ$129$VRQXoODUÕ ... 69

Tablo 5.7. *|POHNLoLQ$129$VRQXoODUÕ ... 69

Tablo 5.8. $úÕQPDND\ÕSODUÕLoLQGR÷UXODPDGHQH\OHULVRQXoODUÕ ... 71

xii

g=(7

Anahtar kelimeler: 3LVWRQVHJPDQÕ0ROLEGHQWR]X$úÕQPDWHVWL7DJXFKL0HWRGX

%X oDOÕúPDGD 0ROLEGHQ tozu NDSOÕ SLVWRQ VHJPDQODUÕQÕQ DúÕQPD GDYUDQÕúODUÕ

LQFHOHQPLú YH DúÕQPD SDUDPHWUHOHUL RSWLPL]H HGLOPLúWLU $úÕQPD GHQH\OHULnde PLQLPXPDúÕQPDND\EÕHOGHHWPHNLoLQ\NVÕFDNOÕNYHGHYLUDúÕQPDSDUDPHWUHOHUL

Taguchi metodunun L27 GL]LVLQHJ|UHRSWLPL]HHGLOPLúWLU'HQH\VRQXoODUÕQGDQKHP

VHJPDQ KHP GH VLOLQGLU J|POH÷LQLQ PLQLPXP DúÕQPD ND\EÕ LoLQ HQ HWNLOL IDNW|UQ

\N ROGX÷X WHVSLW HGLOPLúWLU 5HJUHV\RQ DQDOL]L NXOODQÕODUDN PDWHPDWLNVHO PRGHOOHU

HOGH HGLOPLúWLU 2SWLPL]DV\RQ \|QWHPLQLQ GR÷UXODPD GHQH\L sonucu ile deneysel VRQXoODUELUELULQHROGXNoD \DNÕQoÕNPÕúWÕU6HJPDQYHVLOLQGLUJ|POH÷L LoLQDúÕQPD

KDULWDODUÕ ROXúWXUXOPXúWXU $úÕQPD \]H\OHULQLQ DQDOL] VRQXFX DEUDVLI DúÕQPD

PHNDQL]PDVÕQÕQEDVNÕQROGX÷XQXJ|VWHUPLúWLU

xiii

INVESTIGATION AND OPTIMIZATION OF WEAR BEHAVIORS OF PISTON RINGS COATED WITH MOLYBDENUM POWDER SUMMARY

Key Words: Piston ring, molybdenum powder, Wear test, Taguchi Method.

In this study, wear behaviors of piston rings coated with molybdenum powder have been investigated and wear parameters optimized. Wear process parameters are optimized for minimum weight loss and friction based on L₂₇Taguchi method with three wear parameters, load, temperature and revolution.It is determined that the load have the most significant factor influence on minimum weight loss of both the piston rings and the cylinder liner. Mathematical models of weight loss have been obtained using Regression analyzes.The predicted weight loss in confirmation test has been found to lie close to that of the experimentally observed ones. Wear maps have been created for piston ring and cylinder liner. Analysis results of worn surfaces shows

that abrasive wear mechanism is more effective.««««««««««««««

%g/h0 *ø5øù

$úÕQPDELUELUOHUL\OHWHPDVKDOLQGHRODQLNL FLVPLQED÷ÕOKDUHNHWLVRQXFXFLVLPOHULQ

\]H\OHULQGHPH\GDQDJHOHQPDO]HPHND\EÕGÕU%XQGDQGROD\ÕFLVLPOHULONúHNLOOHUL

YHER\XWODUÕQÕND\EHGLSEHNOHQHQIRQNVL\RQODUÕ\HULQHJHWLUHPH]OHU$úÕQPDVDGHFH

ELUPDO]HPH|]HOOL÷LGH÷LOD\QÕ]DPDQGDDúÕQDQ\]eyleri meydana getiren sistemin YHUPLúROGX÷XFHYDSWÕU(Bhushan, 2002)$úÕQPDHQGVWULGHNRUR]\RQYH\RUXOPDQÕQ

KDULFLQGH HQ oRN úLNk\HW HGLOHQ NRQXODUÕQ EDúÕQGD JHOPHNWHGLU %X \]GHQ

HQGVWULGHNLoDOÕúPDODUVUWQPHYHDúÕQPD\ÕD]DOWPDYH\DNRQWURODOWÕnda tutmaya

\|QHOLNRODUDNJHUoHNOHúWLULOPHNWHGLU

øoWHQ \DQPDOÕ PRWRUODUGD VUWQPH WRSODP Jo ND\EÕQÕQ |QHPOL ELU E|OPQ

ROXúWXUPDNWDGÕU øoWHQ \DQPDOÕ PRWRUODUGD PRWRU LoL VUWQPHQLQ HQ |QHPOL

HWNHQOHUGHQ ELUL SLVWRQ JUXEXGXU 3LVWRQ JUXEX VUWnmesi toplam motor VUWQPHVLQLQ \DNODúÕN  -¶ LQL ROXúWXUPDNWDGÕU 6LOLQGLU J|POH÷L-piston ve SLVWRQVHJPDQÕVUWQPHVLSLVWRQJUXEXVUWQPHND\EÕQÕQ\DNODúÕNWDPDPÕGÕULin, 1993-.DSVÕ] 2011). øoWHQ \DQPDOÕ PRWRUODUGD VUWQPH YH DúÕQPD\Õ L\LOHúWLUPHN

LoLQ\D÷ODPDYHPDO]HPH|]HOOLNOHULQLQL\LELOLQPHVLJHUHNLU

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\HULQHJHWLUHQNDWÕKDOGHNL\D÷OD\ÕFÕWUOHULGLU%XNDWÕ\D÷OD\ÕFÕODUND\PDHVQDVÕQGD

oRNGúNVUWQPHYHRUWDúLGGHWHDúÕQPDGDYUDQÕúÕVHUJLOH\HELOLUOHU(Q\D\JÕQNDWÕ

\D÷OD\ÕFÕWUOHULJUDILW0ROLEGHQ'LVOILW0R62) ve bunlara ilaveten PTFE olarak bilinmektedir.

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MoS2 PDGHQVHO \]H\OHULQ ]HULQGH ELU WDEDND ROXúWXUXU %X WDEDNDQÕQ ROXúPDVÕ

hava YH\DVX\DED÷OÕGH÷LOGLU%XQHGHQOHYDNXPGDYH\DRGDVÕFDNOÕ÷ÕQGDPROLEGHQ

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kaplama malzemesLRODUDNNXOODQÕOPDNWDGÕU

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Canale ve Ark (Canale, 2005) GúN VÕFDNOÕNODUGD NDWÕ \D÷ODPD LOH \]H\

NDUDNWHULVWLNOHULQL YH WULERORMLN |]HOOLNOHUL DUDúWÕUPÕúODUGÕU dHOLNWHQ UHWLOHQ silindir J|POH÷LQH oLIW NDSOÕ PROLEGHQ tozunu iyon ve protonOX \]H\ NDSODPD \|QWHPL

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