Application of Supersonic Flame Spraying for Next Generation Cylinder Liner Coatings

2012 ◽  
Vol 533 ◽  
pp. 91-97 ◽  
Author(s):  
Andrei Manzat ◽  
A. Killinger ◽  
R. Gadow
Keyword(s):  
Corrosion Resistance ◽  
Surface Topography ◽  
High Performance ◽  
Combustion Engine ◽  
Cylinder Liner ◽  
Flame Spraying ◽  
Oil Consumption ◽  
Functional Coatings ◽  
Coating Materials ◽  
Cylinder Liners

Rising demands for ecologically friendly automotive engines require a significant decrease in fuel consumption and emissions. Also the recent trend of downsizing engines demands for high performance materials for internal combustion engine applications. Tribologically functional coatings applied by supersonic flame spraying help in boosting the engine efficiency 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 of the thermal spray coatings help in supporting advantageous friction states and thereby show the benefit of reducing the oil consumption resulting in reduced emissions. 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 and corrosion resistance, friction coefficient and effects of the surface topography have been investigated in various test setups including engine tests.

A Finite Element Numerical Methodology for the Fatigue Analysis of Cylinder Liners of a High Performance Internal Combustion Engine

2019 ◽  
Vol 827 ◽  
pp. 288-293 ◽  
Author(s):  
Saverio Giulio Barbieri ◽  
V. Mangeruga ◽  
Matteo Giacopini ◽  
Carlo Laurino ◽  
Mariano Lorenzini
Keyword(s):  
Finite Element ◽  
High Performance ◽  
Linear Models ◽  
Combustion Engine ◽  
Cylinder Liner ◽  
Fatigue Behaviour ◽  
Load Cycle ◽  
Computational Effort ◽  
Simplified Approach ◽  
Cylinder Liners

In this paper a numerical methodology is proposed, which aims at predicting the fatigue behaviour of engine cylinder liners in an eight-cylinder V-type four-stroke turbocharged engine. A preliminary kinematic and dynamic study of the crank mechanism is fulfilled in order to properly identify the load cycle that involves the cylinder liner. Finite Element analyses, both thermal and thermo-mechanical, are performed to evaluate the stress and the strain of the component. In particular, non-linear models are developed to mimic the piston-liner interaction when subjected to different loading conditions. A simplified approach is proposed in order to reduce the computational effort of the simulations. FEM results are then processed employing the multiaxial Dang Van fatigue criterion.

Determination of fundamental parameters for the cross-hatched cylinder liner micro-geometry

2016 ◽  
Vol 231 (3) ◽  
pp. 293-301 ◽  
Author(s):  
N Biboulet ◽  
H Bouassida ◽  
J Cavoret ◽  
AA Lubrecht
Keyword(s):  
Cylinder Liner ◽  
Major Influence ◽  
Oil Consumption ◽  
Fundamental Parameters ◽  
Pressure Distributions ◽  
Load Carrying ◽  
Surface Measurements ◽  
Liner Surface ◽  
Cylinder Liners

This paper is part of a project aiming at optimizing the cylinder-liner/piston-ring contact performance: oil consumption, friction and wear. The surface micro-geometry has a major influence on these characteristics. Classical cylinder-liners display cross-hatched patterns. Grooves modify contact pressure distributions and act as lubricant reservoirs and pipes redistributing oil. The load-carrying capacity is greatly influenced by the number of grooves and their geometry. An automatic groove geometry identification (depth, width, angle) is performed on cylinder-liner surface measurements. The surfaces were measured at two instants: new and after a fired engine test. The micro-geometry evolution is discussed.

Ceramic Layer Composites in Advanced Automotive Engineering and Biomedical Applications

2007 ◽  
Vol 333 ◽  
pp. 177-194
Author(s):  
Rainer Gadow
Keyword(s):  
Biomedical Applications ◽  
High Performance ◽  
Cylinder Liner ◽  
Flame Spraying ◽  
Robot Kinematics ◽  
Light Weight ◽  
Operational Load ◽  
Macro Scale ◽  
Novel Material ◽  
High Flexibility

Light weight engineering and composite technologies are key strategies in modern product development in mechanical engineering as well as in biomedical applications, where innovation is driven by novel material concepts and surface functionalities. Designed or customized surface properties by advanced coating technologies are an important discipline in this context. Ceramic, metallurgical and cermet layers can be manufactured in a most appropriate way by high energetic thermokinetic deposition techniques like plasma spraying, electric arc and last not least by supersonic flame spraying (HVOF). These technologies perform high deposition rates, high flexibility to use various materials and their combinations and applications in micro to macro scale products. The final properties of the coatings and layer composites do not just depend on the properties of the combined materials but, as in the case of ceramic coated light metals, are distinctly affected by the occurring residual stresses and their interaction with operational load stresses. With respect to the complex geometries of most components, their dimensional and positional tolerances a further strong influence of the robot kinematics of the plasma or HVOF torches during coating manufacturing is observed. By combining the expertise in materials and manufacturing engineering coatings and composites with high performance and reliability can be achieved. This is shown in the development of functionally coated cylinder liners and crankcases for ultra light weight engines as well as for ceramic coated bioinert and biodegradable substrates in medical surgery. It will be shown that cast engine block bores can be directly coated by using an automated HVOF process, obtaining improved coating results. The internal coating process by hypersonic flame spraying is a superior technological alternative to the APS process for high quality cylinder liner and engine crankcase applications. The applications of such ceramic and cermet coatings are not limited to automotive and biomedical applications, i. e. for wear and friction properties or biomedical compatibility, but can be used for tailored thermophysical, electrophysical or catalytic properties in various technical systems.

Wear Resistance of Smooth Automotive Cylinder Liner Surfaces

2005 ◽  
Author(s):  
C. Anderberg ◽  
S. Johansson ◽  
P. H. Nilsson ◽  
R. Ohlsson ◽  
B. G. Rose´n
Keyword(s):  
Fuel Consumption ◽  
Piston Ring ◽  
Functional Performance ◽  
Cylinder Liner ◽  
Engine Oil ◽  
Oil Consumption ◽  
Smooth Cylinder ◽  
Liner Surface ◽  
Oil Fuel ◽  
Cylinder Liners

Demands for decreased environmental impact from vehicles are resulting in a strong push for decreased engine oil, fuel consumption and weight. New machining and coating technologies have offered ways to attack these problems. Engine oil and fuel consumption are to a great extent controlled by the topography of the cylinder liner surface and it is therefore important to optimise this surface. Recent engine tests have shown a reduction in oil consumption when using cylinder liners with a smoother finish than that given by the current plateau honing. However, engine manufacturers are hesitant to introduce smoother liner surfaces because of fears of severe wear and scuffing. There is also the possibility that smoother liner surfaces may be more sensitive to the choice of piston ring finishes. This paper therefore seeks to investigate the functional performance and resistance to wear of these smooth cylinder liners and the mating top ring surfaces.

scholarly journals Effects of alloy compositions on mechanical properties of as-cast banite iron materials for cylinder liners

2021 ◽  
pp. 2141008
Author(s):  
Hao Gao ◽  
Kun-Chieh Wang ◽  
Long Wu ◽  
Guangdong Gao ◽  
Dong Liu ◽  
...  
Keyword(s):  
Mechanical Properties ◽  
Tensile Strength ◽  
High Pressures ◽  
Combustion Engine ◽  
High Surface ◽  
Surface Hardness ◽  
Cylinder Liner ◽  
High Price ◽  
Liner Material ◽  
Cylinder Liners

The cylinder liner is a key part of an internal combustion engine. It always exposes at the worst conditions in the engine room: high temperatures, high pressures, large frictions, and large applying forces. Therefore, excellent physical properties such as surface hardness, tensile strength, heat resistance, and pressure resistance are essentially required as a cylinder liner material. Among them, the surface hardness and tensile strength are the most important properties which play decisive roles in producing a good cylinder liner. Researches on the development of new cast materials with different contents of alloying elements used in cylinder liners, which may exhibit high surface hardness as well as tensile strength, consistently draw much attention. In this regard, this study aims to experimentally investigate the effects of alloy compositions on the mechanical properties of ASBC materials for cylinder liners. Besides, we also replace the traditional-used high-price Ni with low-price Cu in order to reduce the production cost of cylinder liner materials. Results show that the best contents of C, Mo, and Cu for an as-cast banite iron (ACBI) material are found around 2.7%, 0.6–0.8%, and 0.82–1.0%, respectively, in which the highest hardness occurs. Those are found around 2.7%, 0.7–0.8%, and 0.94–1.0%, respectively, in which the highest tensile strength occurs. At the same time, without any reductions in performances of hardness and tensile strength, we successfully adopt Cu as a substitute for Ni as an important composition of ACBI material for cylinder liners.

scholarly journals Functional Coatings for Orthodontic Archwires—A Review

Materials ◽  
2020 ◽  
Vol 13 (15) ◽  
pp. 3257 ◽  
Author(s):  
Justyna Bącela ◽  
Magdalena Beata Łabowska ◽  
Jerzy Detyna ◽  
Anna Zięty ◽  
Izabela Michalak
Keyword(s):  
Mechanical Properties ◽  
Corrosion Resistance ◽  
Surface Topography ◽  
Treatment Time ◽  
Orthodontic Appliances ◽  
Functional Coatings ◽  
Nickel Ions ◽  
Orthodontic Archwires

In this literature review, the current state-of-art of coatings for orthodontic archwires’ increasing antimicrobial and relevant mechanical properties, such as surface topography, friction or corrosion resistance, has been presented. There is a growing request for orthodontic appliances, therefore, most researchers focus on innovative functional coatings to cover orthodontic archwires and brackets. Orthodontic appliances are exposed to the unfavorable oral cavity environment, consisting of saliva flow, food, temperature and appliance force. As a consequence, friction or biocorrosion processes may occur. This can affect the functionality of the orthodontic elements, causing changes in their microstructure, surface topography and mechanical properties. Furthermore, the material which the orthodontic archwire is made from is of particular importance in terms of the possible corrosion resistance. This is especially important for patients who are hypersensitive to metals, for example, nickel, which causes allergic reactions. In the literature, there are some studies, carried out in vitro and in vivo, mostly examining the antibacterial, antiadherent, mechanical and roughness properties of functional coatings. They are clinically acceptable but still some properties have to be studied and be developed for better results. In this paper the influence of additives such as nanoparticles of silver and nitrogen-doped TiO2 applied on orthodontic brackets by different methods on the antimicrobial properties was analyzed. Future improvement of coating techniques as well as modification of the archwire composition can reduce the release of nickel ions and eliminate friction and bacterial adhesion problems, thus accelerating treatment time.

Nanocomposite coatings on steel for enhancing the corrosion resistance: A review

2019 ◽  
Vol 54 (5) ◽  
pp. 681-701 ◽  
Author(s):  
AV Radhamani ◽  
Hon Chung Lau ◽  
S Ramakrishna
Keyword(s):  
Corrosion Resistance ◽  
High Performance ◽  
Low Cost ◽  
Offshore Structures ◽  
Nanocomposite Coating ◽  
Coating Materials ◽  
High Mechanical Strength ◽  
Ship Building ◽  
Corrosion Of Steel ◽  
Deposition Techniques

Steel is known for its low cost of fabrication, high mechanical strength and hence is extensively used for drilling equipment, pipelines, ship building and offshore structures. Corrosion of steel is a costly problem in many applications especially in oilfield and marine environments which are known for the high temperature, high pressure and corrosive conditions. In this paper, nanocomposite coating is being explored as the preferred strategy to improve corrosion resistance for steel. Here, we will give details on the various coating materials, deposition techniques and the challenges involved in realising the most suitable coating on steel based on results of recent research. In addition, we also detail the filler specifications for getting high performance nanocomposites.

scholarly journals Investigation of Reciprocating Conformal Contact of Piston Skirt-to-Surface Modified Cylinder Liner in High Performance Engines

2005 ◽  
Vol 219 (11) ◽  
pp. 1235-1247 ◽  
Author(s):  
S Balakrishnan ◽  
S Howell-Smith ◽  
H Rahnejat
Keyword(s):  
High Speed ◽  
High Performance ◽  
Cylinder Liner ◽  
Operating Conditions ◽  
Contact Forces ◽  
Piston Skirt ◽  
Lubrication Condition ◽  
Surface Modified ◽  
Cylinder Liners ◽  
Film Lubrication

The article presents detailed analysis of the conforming contact between a piston and cylinder liner in a high-speed racing engine under extreme operating conditions owing to high loads and operating speeds in excess of 19 000 r/min, resulting in a high sliding velocity of 42 m/s. The analysis indicates contact forces generated in the order of 2.5 kN. The contribution due to fluid film lubrication is found to reside in iso-viscous rigid or elastic regimes of lubrication, which is insufficient to form a coherent lubricant film during some parts of the cycle, such as at top-dead-centre (TDC). The article shows that at combustion, 95 per cent of the contact can remain in boundary or mixed regimes of lubrication. Piston skirt surface modification features are used in conjunction with an electrolytically applied composite coating, Ni[SiC]p to produce advanced cylinder liners to remedy the situation. Detailed numerical analysis shows that significant improvement is achieved in the regime of lubrication condition.

scholarly journals Assessment of friction from compression ring conjunction of a high-performance internal combustion engine: A combined numerical and experimental study

2015 ◽  
Vol 230 (12) ◽  
pp. 2073-2085 ◽  
Author(s):  
M Gore ◽  
R Rahmani ◽  
H Rahnejat ◽  
PD King
Keyword(s):  
High Performance ◽  
Combustion Engine ◽  
Viscous Friction ◽  
Cylinder Liner ◽  
Lubricant Film ◽  
Film Rupture ◽  
Compression Ring ◽  
Piston Cylinder ◽  
Direct Measurements ◽  
Good Agreement

The paper presents direct measurement of in-cylinder friction from a single cylinder motocross race engine under motored conditions and compares the same with a new analytical predictive method. These conditions are encountered in piston–cylinder system with the application of cylinder deactivation (CDA) technology, which is a growing trend. The analytical method takes into account the various regions within instantaneous contact of compression ring–cylinder liner, including lubricant film rupture, cavitation zone and the subsequent lubricant film reformation. The analysis also includes the effect of boundary friction and lubricant rheology. The predictions and direct measurements of cyclic friction show good agreement and indicate dominance of viscous friction under the investigated engine running conditions. In particular, it is shown that the compression ring contribution to in-cycle friction is most pronounced in the region of high cylinder pressures because of combined Poiseuille friction and some boundary solid interactions. The combined experimental-analytical approach has not hitherto been reported in literature.

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