Thermally Sprayed Coatings For Engine Applications
Michael Buchmann, Rainer Gadow, Andreas Killinger
Institute for Manufacturing Technologies of Ceramic Components and Composites
abstract:Recent automotive engineering developments concerning fuel consumption regulations and decreasing material and manufacturing cost result in an increasing utilization of light metal components for automotive applications. Significant weight savings are obtained by a modification of the engine block material from cast iron to aluminum. Since all parts of a combustion engine interact as a system the single components must sustain the combustion pressure and temperature as well as wear and friction effects of moving surfaces in different environment and lubrication. Approaches to increase efficiency and lifetime of light metal engine blocks are protective thermally sprayed coatings on the cylinder bores. The used thermal spray processes are high-energetic (Atmospheric Plasma Spraying) and high-energetic hypersonic processes (High Velocity Oxygen Fuel Spraying). The knowledge of the mechanical and thermophysical properties of the composite materials is a key requirement for an optimized stable and repeatable manufacturing process as well as for reproducible high quality composites. This paper describes an actual overview about the material screening, the manufacturing technology and measured coating characteristics. Residual stress measurements are performed and the effects on the coating properties like bonding, hardness, friction and wear are investigated.
keywords:thermophysical properties; cylinder; Residual; bores; light metal; engine block; wear and friction; thermal spray
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