24. Ceramic and Cermet Coatings for Cylinder Liners in Ultra-Light Weight Engines

  1. Dongming Zhu and
  2. Kevin Plucknett
  1. Antonio Candel,
  2. Rainer Gadow and
  3. Daniel López

Published Online: 26 MAR 2008

DOI: 10.1002/9780470291238.ch24

Advances in Ceramic Coatings and Ceramic-Metal Systems: Ceramic Engineering and Science Proceedings, Volume 26, Number 3

Advances in Ceramic Coatings and Ceramic-Metal Systems: Ceramic Engineering and Science Proceedings, Volume 26, Number 3

How to Cite

Candel, A., Gadow, R. and López, D. (2005) Ceramic and Cermet Coatings for Cylinder Liners in Ultra-Light Weight Engines, in Advances in Ceramic Coatings and Ceramic-Metal Systems: Ceramic Engineering and Science Proceedings, Volume 26, Number 3 (eds D. Zhu and K. Plucknett), John Wiley & Sons, Inc., Hoboken, NJ, USA. doi: 10.1002/9780470291238.ch24

Author Information

  1. University of Stuttgart Allmandring 7 b D-70569 Stuttgart, Baden-Wurttemberg, 70569

Publication History

  1. Published Online: 26 MAR 2008
  2. Published Print: 1 JAN 2005

ISBN Information

Print ISBN: 9781574982336

Online ISBN: 9780470291238

SEARCH

Keywords:

  • pollution;
  • aluminum;
  • hypersonic;
  • velocity;
  • magnesium

Summary

Actual necessities in the automotive industry are die reduction of fuel consumption and pollution emission, engine efficiency improvement, as well as cost reduction. Most of these requirements are fulfilled by reducing the total weight of the vehicle. This results in an increasing utilization of light metal components for engine applications. Significant weight savings are obtained by changing the engine block material from cast iron to aluminum.

Despite of all advantages the industrial implementation of light metals is often inhibited by their poor surface properties especially concerning wear and tribological behavior. Due to the highly loaded operation conditions a cylinder liner surface reinforcement is necessary.

A very promising technological alternative is the internal cylinder reinforcement by using HVOF (high velocity oxygen fuel) spray coatings. By using these advanced high energetic coating technologies, material combinations containing solid lubricant ceramic dispersions can be deposited. The thermal spray processes represent a cost effective and flexible solution for ultra light weight engine technology. This research is focused on the development of HVOF sprayed coating systems for cylinder liners, the coating optimization and the cost effective implementation of this hypersonic spray technology in a series production process.

It will be shown mat 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.