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2708 |
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Wednesday, September 28, 2011, Saal C2.1 11:50 AM Automotive Industry 1 |
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Supersonic flame sprayed cylinder liner coatings and the benefits of their intrinsic porosity
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Andrei Manzat* / IFKB University of Stuttgart, Germany Andreas Vogel / Institute for Manufacturing Technologies of Ceramic Components and Composites (IFKB), Germany Andreas Killinger/ Institute for Manufacturing Technologies of Ceramic Components and Composites (IFKB), Germany Rainer Gadow/ Institute for Manufacturing Technologies of Ceramic Components and Composites (IFKB), Germany |
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Rising demands for ecologically friendly automotive engines require a significant decrease in fuel consumption and emissions. Tribologically functional coatings applied by supersonic flame spraying help in boosting the efficiency of internal combustion engines by reducing the internal friction and improving the durability and wear resistance of the cylinder running surface much-needed for engine downsizing tasks together with a high corrosion resistance enabling the use of bio fuels. In addition, the tailored surface topography, including the intrinsic porosity, of the thermal spray coatings shows the benefit of reducing the friction by sustaining the hydrodynamic friction states even in areas with low relative movement speeds resulting in lower wear, especially in the top dead center area. On top, the open surface porosity reduces the oil consumption and thereby decreases the polluting emissions of internal combustion engines. The thermally sprayed coatings were applied using HVOF and HVSFS processes together with a specially designed spray gun trajectory in order to achieve a fast and cost efficient coating procedure. Several different coating materials, including novel nanostructured powders, have been investigated and compared to state-of-the-art cylinder liners. The performance of the coated cylinder liners regarding wear, friction coefficient and effects of the surface topography represent a new approach to enhance the performance of conventional materials and components of internal combustion engines. |