Different thermal spray processes are being used to provide coatings for cylinder bores in automotive engines. The internal plasma spraying technology described in this paper applies protective layers to cylinder surfaces in engine blocks made of AlSi cast alloys. This method enables a significant reduction in the coefficient of friction, a reduction in oil consumption, and an increase in wear resistance compared to cast iron, the standard material for cylinder liners. Paper includes a German-language abstract.

In the automotive industry, efforts to lower the cost of manufacturing and reduce the weight of an automobile are an ongoing process. Plasma spraying of cylinder bores on engine blocks made of light cast alloys has been developed over the five years. This paper provides an overview of the actual situation of the technology for coating cylinder bores, from cast material to non-destructive testing. The aspects of both finishing using honing technology and testing are to be seen as an important part of plasma spray technology for cylinder bores. The paper discusses the results of laboratory and field tests in Europe, Japan, and the United States. This shows that the plasma spraying process is a proven and cost-effective solution for coating cylinder bores. The launch aspect is also discussed. Paper includes a German-language abstract.