Pulse Eletrodeposition of Ni/nano-Al2O3 Composite Coatings on Cast Iron Cylinder Liner

Abstract The paper deals with effect of working gas pressure and temperature on surface stereometry of coatings deposited by low-pressure cold spray method. Examinations were focused on aluminium coatings which are commonly used to protect substrate against corrosion. A commercial Al spherical feedstock powder with admixture of Al2O3 (Al + 60vol.-% Al2O3), granulation -50+10 µm, was used to coat steel, grade S235JR. Thedeposited coatings were studied to determine their stereometry, i.e. roughness, transverse and longitudinal waviness, topography of surface and thickness as the functions of gas pressure and temperature. A profilometer and focal microscope were used to evaluate the stereometric properties. In order to reduce the number of variables, the remaining process parameters, i.e. shape and size of de Laval nozzle, nozzle-to-substrate distance, powder mass flow rate, linear velocity of spraying gun, were kept unchanged. The investigation confirmed influence of temperature and pressure on coating thickness as well as on the surface seterometry.

Download Full-text

Wear Properties and Scuffing Resistance of the Cr–Al2O3 Coated Piston Rings: The Effect of Convexity Position on Barrel Surface

Journal of Tribology ◽

10.1115/1.4041215 ◽

2018 ◽

Vol 141 (2) ◽

Cited By ~ 4

Author(s):

Siqi Ma ◽

Wenbin Chen ◽

Chengdi Li ◽

Mei Jin ◽

Ruoxuan Huang ◽

...

Keyword(s):

Cast Iron ◽

Friction Coefficient ◽

Surface Morphology ◽

Pressure Distribution ◽

Cylinder Liner ◽

Wear Loss ◽

Wear Properties ◽

Piston Rings ◽

Oil Film ◽

Influencing Mechanism

This work investigates the effect of convexity position of ring barrel surface on the wear properties and scuffing resistance of the Cr–Al2O3 coated piston rings against with the CuNiCr cast iron cylinder liner. The scuffed surface morphology and elements distribution as well as the oil film edge were analyzed to explore the influencing mechanism of the convexity position on the scuffing resistance. The results show that the convexity offset rate on the barrel surface of the ring has no noticeable influence on both friction coefficient and wear loss near the dead points, but a suitable convexity position will result in the improved scuffing resistance. The shape of the barrel face not only affects the worn area on the ring, but also determines the oil film wedge and pressure distribution, consequently influences the scuffing resistance.

Download Full-text

A Study of Parameters Affecting Wear Resistance of Alumina and Yttria Stabilized Zirconia Composite Coatings on Al-6061 Substrate

ISRN Ceramics ◽

10.5402/2012/585892 ◽

2012 ◽

Vol 2012 ◽

pp. 1-13 ◽

Cited By ~ 6

Author(s):

N. Krishnamurthy ◽

M. S. Prashanthareddy ◽

H. P. Raju ◽

H. S. Manohar

Keyword(s):

Internal Combustion Engines ◽

Composite Coatings ◽

Wear Test ◽

Cylinder Liner ◽

Yttria Stabilized Zirconia ◽

Atmospheric Plasma ◽

Equal Proportion ◽

Stabilized Zirconia ◽

Bond Coats ◽

Al 6061

In this investigation, a composite coating of alumina and yttria stabilized zirconia in equal proportion was developed on Al-6061 substrate using Atmospheric Plasma Spraying technique. Two commercially available powders of chemical composition Al 25Fe7Cr5Ni and Al2O330(Ni 20Al) were used as bond coats. The coating samples were subjected to abrasive wear test as per ASTM G99. From the results it was found that wear rate and coefficient of friction depend on various parameters such as microstructure, surface roughness, porosity, coating thickness, and hardness. It was also found that the mechanism of wear is mainly due to abrasion and once the bond coat is exposed to the disc, it loses material by adhesion. As the coating systems possess α-Al2O3 and ZrO2, they can be used for wear and heat resistant applications such as cylinder liner of internal combustion engines.

Download Full-text

Effect of jet electrodeposition conditions on microstructure and mechanical properties of Cu–Al2O3 composite coatings

The International Journal of Advanced Manufacturing Technology ◽

10.1007/s00170-019-03419-5 ◽

2019 ◽

Vol 105 (11) ◽

pp. 4509-4516 ◽

Cited By ~ 3

Author(s):

Hui Fan ◽

Yangpei Zhao ◽

Shankui Wang ◽

Huafeng Guo

Keyword(s):

Mechanical Properties ◽

Composite Coatings ◽

Microstructure And Mechanical Properties ◽

Al2o3 Composite ◽

Jet Electrodeposition

Download Full-text

Wear Behavior of CuSn Coated Piston Ring Sliding against Nodular Cast Iron Cylinder Liner under Heavy-Duty Conditions

Metals ◽

10.3390/met9020139 ◽

2019 ◽

Vol 9 (2) ◽

pp. 139 ◽

Cited By ~ 1

Author(s):

Wenhua Li ◽

Baihong Yu ◽

Yutao Lv ◽

Yan Shen ◽

Ruoxuan Huang ◽

...

Keyword(s):

Cast Iron ◽

Piston Ring ◽

Chemical Elements ◽

Wear Behavior ◽

Cylinder Liner ◽

Nodular Cast Iron ◽

Wear Loss ◽

Heavy Duty ◽

Liner Surface ◽

Cr Coating

In order to investigate the friction and wear behavior between the nodular cast iron cylinder liner (Fe) and CuSn coated piston ring under heavy-duty conditions, piston rings with chromium(Cr) coating and CuSn-Cr coating were tested using the piston ring reciprocating liner test rig at the simulated working conditions of 56 MPa, 200 r/min, 190 °C. Compared with the Cr/Fe pair, the CuSn coating consumption of the CuSn-Cr/Fe pair made friction coefficient and cylinder wear loss decrease by 2.8% and 51.5%, respectively. Different size Sn patches worn from the CuSn coated piston ring were embedded into the cylinder liner surface based on the surface topography. This process was shown to reduce the surface roughness of a cylinder liner and form flatter plateau structures. Chemical elements analysis indicated that plateau structures on the cylinder liner surface matched with CuSn-Cr coated ring are helpful to promote the tribo-chemical reaction and generate the reactive products to protect the mutually contacted asperities.

Download Full-text

Tribological assessment of NiCr, Al2O3/TiO2, and Cr3C2/NiCr coatings applied on a cylinder liner of a heavy-duty diesel engine

International Journal of Engine Research ◽

10.1177/1468087420930164 ◽

2020 ◽

pp. 146808742093016

Author(s):

Onur Biyiklioğlu ◽

Mustafa Ertunc Tat

Keyword(s):

Cast Iron ◽

Diesel Engine ◽

Wear Rate ◽

Gray Cast Iron ◽

Cylinder Liner ◽

Gray Cast ◽

Economic Evaluations ◽

Heavy Duty ◽

Heavy Duty Diesel Engine ◽

Heavy Duty Diesel

Internal combustion engines consume about 90% of fuel refined from crude oil which supplies 30% of the annual global flow of energy. Heavy-duty diesel engines are the primary source of power used in highways, marine, railroads, and power stations. The right coating can improve the tribological properties of cylinder liners and increase the mechanical efficiency of an engine. Also, it can help to extend the maintenance periods, and enhance the reliability of the vehicles. In this research, tribological and economic evaluations were performed for coated and uncoated substrates from a cylinder liner of a heavy-duty diesel engine, aiming to lower friction, wear rate, and maintenance cost. A reciprocating friction test was conducted under dry condition using Wolfram carbide (tungsten carbide) ball applied a 10 N normal load on a ball on disk geometry. The cylinder liner was made of gray cast iron, and the substrates obtained were coated with three different coating materials (Cr3C2/NiCr, NiCr, and Al2O3/TiO2) through the thermal spray and high-velocity oxy-fuel coating process. Tribological evaluations showed that the substrates coded with Al2O3/TiO2 and Cr3C2/NiCr had the lowest friction coefficient and wear rate. The most economical coating was Al2O3/TiO2, being able to supply about 61% lower coefficient of friction and 94% less wear rate relative to the uncoated sample, for the price of one-third of the Cr3C2/NiCr coating and one half of a new gray cast iron cylinder liner.

Download Full-text