Development of Novel Fe-Based Coating Systems for Internal Combustion Engines

Abstract

Abstract 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.