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Advanced hypersonic flamespray coatings for cylinder liners in light metal engines

机译：浅色金属发动机气缸衬套的先进超音速火焰涂层

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The reduction of fuel consumption and pollution emissions, the improvement of the engine efficiency as well as the cost reduction in manufacturing and assembly are in the focus of actual research activities in the automotive industry. Most of these requirements can be fulfilled by a reduction of the total vehicle weight. This results in an increasing utilization of light metals for chassis, body and engine components. Significant weight savings are obtained by changing the engine block material from cast iron to aluminum. Due to the harsh operation conditions, the aluminum cylinder must be reinforced. Approaches to increase combustion as well as operation efficiency and lifetime of light metal engines are thermally sprayed APS (Atmospheric Plasma Spraying) and HVOF (High Velocity Oxygen Fuel Spraying) coatings on cylinder liners of the aluminum crankcases. By using this coating technologies, also material combinations containing solid lubricant dispersions can be deposited. The thermal spray processes represent a cost-effective and flexible solution for the engine technology. Meanwhile, APS coatings for 4-cylinder engine blocks are produced in series production. Actual research activities are focused on the development of advanced HVOF- sprayed coating systems on cylinder liners, the coating optimization and the cost-effective implementation of this technology in an automated series production process. In hypersonic flame spraying (HVOF), the coating is deposited by an elliptically moving HVOF gun, whereas the cylinder liner is rotating. By HVOF processing an improved coating microstructure (less porosity) and superior coating adhesion is obtained. The HVOF coatings are homogeneous, with a dense, bulk like microstructure, a low porosity (<5%) and surface roughness as well as a superior coating adhesion compared to APS coatings.
机译：减少燃料消耗和污染排放，提高发动机效率以及制造业和装配成本的焦点是汽车行业实际研究活动的重点。大多数这些要求可以通过减少总载体重量来满足。这导致用于底盘，身体和发动机部件的光金属的利用率越来越多。通过将发动机块材料从铸铁更换为铝来获得显着的重量。由于苛刻的操作条件，必须加强铝圆筒。增加燃烧的方法以及轻金属发动机的运行效率和寿命是铝曲柄型汽缸衬套上的热喷涂的AP（大气等离子体喷涂）和HVOF（高速氧气燃料喷涂）涂层。通过使用该涂层技术，还可以沉积含有固体润滑剂分散体的材料组合。热喷涂工艺代表发动机技术的成本效益和灵活的解决方案。同时，用于4缸发动机块的APS涂层串联生产生产。实际研究活动集中在气缸衬套上的先进HVOF喷涂涂层系统，涂层优化和本技术在自动化系列生产过程中的成本效益实施。在高效火焰喷涂（HVOF）中，通过椭圆形的HVOF枪沉积涂层，而汽缸衬套旋转。通过HVOF处理改善的涂层微观结构（较少的孔隙率）和优异的涂层粘附。 HVOF涂层是均匀的，具有致密的体积，如微观结构，低孔隙率（<5％）和表面粗糙度以及与APS涂层相比的优异涂层粘附。

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