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Proceedings Papers
ITSC 2019, Thermal Spray 2019: Proceedings from the International Thermal Spray Conference, 688-694, May 26–29, 2019,
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The aim of this work is to develop and assess an eco-friendly carbon-based composite coating for piston ring applications. The coatings were produced from sugarcane waste and Mo, NiCr, and CrC powders using high-velocity oxyfuel spraying and thermal chemical vapor deposition. SEM-EDS and XRD analysis confirms the presence of carbides and oxides that cause coating hardness to increase with increasing temperature. At 550 °C, under a 20 N load with a sliding velocity 0.3 m/sec, the friction coefficient of the coating was found to be 0.2, the wear value was 130 μm, and friction force was 4N. The results indicate that the friction and wear properties of the coatings improve with increasing temperature due to the formation of tribo-oxidative films and the effects of graphitization associated with the presence of carbon.
Proceedings Papers
ITSC 2017, Thermal Spray 2017: Proceedings from the International Thermal Spray Conference, 228-234, June 7–9, 2017,
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Nowadays combustion engines are the most common way to impel vehicles. Thereby losses occur, due to cooling, exhaust gas and friction. Modern engines roughly dissipate 8% of the chemical energy stored in the fuel because of friction in different tribological systems. The highest potentials for optimisation can be found in the tribological system of inner surface of combustion chamber and piston ring. Besides friction, corrosive stress of inner surface of combustion chamber increases e.g. due to the utilization of auxiliary systems such as Exhaust-Gas-Recovery. In order to save energy, reduce emissions and enhance the lifetime of combustion engines innovative coating material systems need to be developed, especially for inner surface of combustion chamber. This study focuses on the development of innovative iron based materials for combustion chamber application using Plasma Transferred Wire Arc (PTWA) and Rotating Single Wire Arc (RSW) technologies. In order to improve the wear and corrosion resistance boron and chromium are added into the feedstock material. After deposition, different honing topographies are manufactured in order to evaluate their influence on the tribological behavior. Furthermore, electro-chemical corrosion tests are conducted by using an electrolyte simulating the exhaust gas concentrate. In conclusion an optimised coating material deposited by PTWA and RSW and improved surface topographies can be combined.
Proceedings Papers
ITSC 2011, Thermal Spray 2011: Proceedings from the International Thermal Spray Conference, 914-919, September 27–29, 2011,
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The HVOF sprayed wear resistant hardmetal coatings with favourable sliding properties are suitable for increasing the lifetime of sliding applications, such as pistons of combustion engines, pumps and other hydraulic devices. In practice, the coatings face the problem of their interaction with other media, in the case of sliding wear usually lubricants. In the paper, the friction properties of five different HVOF sprayed coatings are evaluated by pin-on-disk test according to ASTM G-99 under dry and lubricated conditions and lubricated block-of-ring test according to ASTM G77. Several types of lubricants designed for combustion engines were used to compare their influence on coatings sliding wear behavior. Based on the results, the suitability of coatings for the application on the engines parts is discussed and the effect of counterpart material and different types of lubricants on the coefficient of friction and coatings wear rate is analyzed. It was confirmed, that the CrC-based coating are more suitable for the application under the condition corresponding to combustion engines, e.g. elevated temperature and steel counterpart, than the WC-based coatings. From the group of CrC-based coatings, the superior behavior was observed at the CrC-CoNiCrAlY coating, the matrix material of which offers further enhancement of the sliding wear behavior.
Proceedings Papers
ITSC 2011, Thermal Spray 2011: Proceedings from the International Thermal Spray Conference, 473-478, September 27–29, 2011,
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In an effort to inhibit a climate change, the European Union has decided to reduce the CO 2 emissions by approx. 30% by year 2020, as compared to the level of emissions in year 1990’s. In general, traffic is responsible for 20% of all CO 2 emissions and 84% of those emissions result specifically from road traffic. In accordance with the present targets of the CO 2 emission reduction the automotive industry has to meet strict regulations. The strict emission goals can only be reached by weight reduction of the vehicle and by an improved efficiency of engine and drive train. Close to 50% of the friction losses in a combustion engine result from the interaction between the piston ring and the cylinder bore surface. Therefore the cylinder bores as well as the piston rings were coated with new, low-friction materials. The friction behaviour was characterized in linear reciprocating tribometer-test in order to identify the best combination of bore and ring coatings.
Proceedings Papers
ITSC 2006, Thermal Spray 2006: Proceedings from the International Thermal Spray Conference, 673-678, May 15–18, 2006,
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HVOF spraying of carbides is a well established method to produce high performance wear and corrosion protection coatings for various industrial applications. Using ultrafine feedstock powders with particle sizes well below 25 µm can offer many advantages with respect to the resulting coating properties, such as improved coating density and homogeneity and high dimensional accuracy. In this study, fine powder grades of WC 10Co 4Cr, WC 17Co and Cr 3 C 2 25(Ni 20Cr) in a particle size range of –15 +5 µm, -10 +3 µm and –5 µm have been sprayed with suitable HVOF systems on outer surfaces as well as on internal diameters. Resulting coatings have been analysed with respect to coating structure and microhardness. The coatings featured a favourable microstructure and very good hardness values. Furthermore, the Cr 3 C 2 25(Ni 20Cr) material was applied as wear protection coating on piston rings. The coating performance was evaluated in engine tests and proved to be significantly better than a conventionally graded standard material system for this application.
Proceedings Papers
ITSC 2003, Thermal Spray 2003: Proceedings from the International Thermal Spray Conference, 129-138, May 5–8, 2003,
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Diesel engine development is continuously progressing: light vehicle diesel (LVD) engines are gaining in popularity in Europe and therefore we see a steady improvement in power performance and fuel consumption going along with increased loading of the power-cylinder components. Moreover, heavy-duty (HD) engines for trucks are facing stricter environmental legislation leading amongst other technologies to the introduction of exhaust gas recirculation (EGR). Whatever reduced emission technology will be applied, they all will significantly influence the engine tribology. This paper is dedicated to describing modern piston ring coating technologies to face the future diesel engine demands. The paper mainly focuses onto modern piston ring coating technology such as hard particle reinforced chrome plating, HVOF spraying and PVD. In particular, it will be discussed how thermal spray coatings need to be designed to find their position among established or future coating technologies of the competition.
Proceedings Papers
ITSC 2003, Thermal Spray 2003: Proceedings from the International Thermal Spray Conference, 139-142, May 5–8, 2003,
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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.
Proceedings Papers
ITSC1999, Thermal Spray 1999: Proceedings from the United Thermal Spray Conference, 128-133, March 17–19, 1999,
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TiC-based coatings sprayed by different processes, such as detonation gun spraying, high velocity oxy-fuel spraying, atmospheric plasma spraying (APS), and vacuum plasma spraying, using agglomerated and sintered powders have been actively developed over the years. This development is based on the high technical and engineering potential of the hard phase TiC. This paper describes the results of basic studies of the APS for various alloying steps in the production of TiC base coatings from agglomerated and sintered powders as well as the results of the application of APS coatings on piston rings. Paper includes a German-language abstract.
Proceedings Papers
ITSC1999, Thermal Spray 1999: Proceedings from the United Thermal Spray Conference, 153-157, March 17–19, 1999,
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This paper describes the development of novel engineered surfaces based on thermal spray coatings for sliding wear resistance under conditions of high loading and starved lubrication. As specific examples, piston ring elements for internal combustion engines and radial bearings for medium-lubricated pumps are discussed. The properties of two coatings, SUME SOL 220 and SUME SOL 320, are compared with existing materials and coatings. It was found that SUME SOL 220 exhibited excellent sliding wear resistance under boundary (oil) lubrication. As a consequence, they are considered as attractive candidates for piston ring applications in heavy duty engines. For more corrosive applications, such as encountered in sea water environments, the SUME SOL 320 coating exhibited superior combinations of sliding wear and corrosion resistance. Paper includes a German-language abstract.
Proceedings Papers
ITSC1997, Thermal Spray 1997: Proceedings from the United Thermal Spray Conference, 1-9, September 15–18, 1997,
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Plasma arc sprayed coatings are largely developed in Perfect Circle Europe because of the wide range of coating materials which ensure numerous tribological properties. Spraying parameters are of great importance in improving the coating structure and therefore the coating wear, adhesive, cohesive and corrosive resistances. The utilized plasma gas is first studied; designed experiments are then achieved to optimize the all spraying parameters. More than the spraying parameters, the powder formulation has a major influence on the coating tribological properties. Several powders are studied with the aim to reduce the ring-liner system wear. Tests on idealized samples coupled with engine tests help us to characterize the tribological behaviour of some molybdenum based coatings.