Surface texturing to promote formation of protective tribofilms on combustion engine valves

Abstract

In a combustion engine, the valve system controls the flow of gases in to and out of the combustion chamber. The contacting surfaces experience a harsh tribological situation with high temperatures, high speed impacts, corrosive environment and high closing forces causing micro sliding in the interface. The components have to endure in the range of hundreds of millions to a billion operational cycles, resulting in extreme demands on low wear rate. Such low wear rates can be accomplished by the protective action from tribofilms forming from oil residues, avoiding a pure metal-to-metal contact. Such tribofilms are found on well-functioning engine valves from a variety of engines, but some stationary gas engines experience problems with wear occurring seemingly randomly at normal running conditions. For some reason, the tribofilm has not protected the surfaces sufficiently, causing wear. One way to combat the random behaviour could be to promote robust function of the protective tribofilms by texturing the valve sealing surfaces to improve the capture and storage of oil residues. By stabilising the supply in this way, the damage from periods with low access to tribofilm forming material could be reduced. The present work demonstrates that turning of the valve seat inserts, creating valleys perpendicular to the sliding motion, can be developed into a useful solution. The amount and localisation of tribofilms became more predictable and stable than without the texture, leading to reduced component wear. The valleys should not be too wide, since this increased the amount of exposed metal if the tribofilm flaked off. When having the same width, the deeper valleys showed less flaking off of the tribofilm.