Optimizing the Cylinder Running Surface / Piston System of Internal Combustion Engines Towards Lower Emissions Sulzer Metco AG (Switzerland)

Format:

Conference/Event

Author/Creator:

Ernst, Ernst, author.

Contributor:

Distler, Bernd

Conference Name:

2012 Small Engine Technology Conference & Exhibition (2012-10-16 : Madison, Wisconsin, United States)

Language:

English

Physical Description:

1 online resource

Place of Publication:

Warrendale, PA SAE International 2012

Summary:

Rising fuel prices and more stringent vehicle emissionsrequirements are increasing the pressure on engine manufacturers toutilize technologies to increase efficiency and reduce emissions.As a result, interest in cylinder surface coatings has risenconsiderably in the past few years. Among these are SUMEBore®coatings from Sulzer Metco. These coatings are applied by apowder-based air plasma spray (APS) process. The APS process isvery flexible, and can process materials which wire-based methodscannot, particularly metal matrix composites and pure ceramics.Applications range from small 2-stroke engines, motorcycles, andlightweight passenger car engines, up to high-speed diesel truckengines and medium-speed diesel engines.The compositions of the coatings can be tailored to the specificchallenges in an engine, e.g., excessive abrasive wear, scuffing,corrosion caused by adulterated fuel, improved heat transfer fromthe combustion chamber into the water jacket, et cetera A number ofengines have been tested successfully. Most of them exhibitedsignificant reductions in lube oil consumption (LOC), reduced fuelconsumption, very low wear rates and corrosion resistance on theliner surfaces. This coating solution has been commercialized invarious markets. It has proven to be suitable for mass productionon both new engine blocks and liners, and for repair of worn-outparts. Such coatings will continue to play an important role whenit comes to reductions of weight and emissions in internalcombustion engines. An example of such a coating solution will beoutlined. It has been carried out in collaboration with BRPPowertrain in Austria on a 1.5L 3-cylinder aluminum engine andtogether with the adjustment of the ring package and the piston areduction of 35% in LOC was achieved. This engine will go intoproduction in September 2012 with limited numbers coated in theSulzer Metco Wohlen facility in Switzerland, until an engineeredcoating system is ready on site to start large series production.More details on the engine performance and design changes made tothe cast aluminum block in order to take full advantage of thecoating on the cylinder running surfaces is presented in the paperfrom Zorn and others

Notes:

Vendor supplied data

Publisher Number:

2012-32-0092

Access Restriction:

Restricted for use by site license