For the deposition of functional coatings in cylinder bores of automotive engines different thermal spray processes are reviewed. Extensive studies of the process reliability have shown that the internal plasma spraying can be used in the industrial area of the automotive industry. Already today this technology is introduced in Europe and major Japanese companies are in an advanced status of evaluation. This paper describes the main processes used for these engine cylinder coatings and gives some results on typical coating characteristics and friction engine tests. It was shown in engine tests that the friction between piston ring and cylinder wall can be significantly reduced. Further the oil consumption can be significantly reduced and the wear resistance increased. The cost of the developed coating solution can be considered as low for this type of application.

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