Bild 1

Report
Friction and wear reduction in
heavy-duty diesel powertrains
Project Wonaco2 - Tribodays, Örnsköldsvik - 2012-11-07
Project Wonaco2
Engine tribology 101
ANS Triboconditioning
Project focus and results
Summary
2
Research project involving ANS, LTU, UU, HH,
Volvo Powertrain and Scania
Funding from ProViking (SSF)
Objective was to assess if Triboconditioning could
be used to reduce friction in diesel engines
Started in mid 2010 and soon to be concluded
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Project Wonaco2
Engine tribology 101
ANS Triboconditioning
Project focus and results
Summary
4
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Friction losses
Heat losses
(exhaust,
cooling, etc.)
60%
Piston
assembly
20%
Crank train
5%
Friction losses
15%
60%
15%
Valve train
Other*
Useful kinetic
energy
25%
* Auxiliary systems, injection pump, etc.
15% of all energy supplied to an engine is lost due to friction
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Project Wonaco2
Engine tribology 101
ANS Triboconditioning
Project focus and results
Summary
7
Process
Fluid
Tool
Steel surface
TEM-image of the coating
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USAGE
CORE METHOD
Turning
F
Tool
Steel surface
APPLICATIONS
Cylinders
Piston pins
Crankshafts
Rockdrills
Hydraulic rods
Turbine shafts
Bearings
Camshafts
v
Honing
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Original surface
Controlled Running-in
Peaks removed (Rpk reduced)
Nano-composite TRIBO-layer
to reduce friction and wear
Triboconditioned
surface
Triboconditioning improves surface finish and deposits
a low-friction tribolayer in one process step
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Amorphous
deposited film
20-100 nm
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Lowered boundary friction
due to easily sheared
nano-composite coating
Surface layer prevents asperity-asperity contacts
and the coating improves oil affinity,
hence the shift to the left of the curve
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Project Wonaco2
Engine tribology 101
ANS Triboconditioning
Project focus and results
Summary
13
•
•
•
•
•
Pressure
Time
Chemistry fluid
Chemistry tool
Temperature
Triboconditioning
How is the topography changed? Before and after?
How fine surfaces can be manufactured?
Can manufacturing steps be replaced?
How do the process parameters effect the surface (chemistry and topography)?
How can the chemistry in the tribolayer be controlled?
What does the film look like? Contents? Hardness? Morphology?
How good are the surfaces in different tribo systems?
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Schematic picture of Scania valve system
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Results – Friction & Wear
Rocker Arm Shaft "ANS3"
0,1
ANS3 Ref1
0,05
ANS3 Ref2
2400
2000
1600
1200
800
400
0
0
Friction koef.
0,15
ANS3 Coating
Wear marks on counter surface after friction test above
From left to right: ANS triboconditioning, Reference 1, Reference 2
Time [s]
Friction reading; ANS triboconditioning vs Reference
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Results – Friction & Wear
Volvo Rocker Arm Shaft "1"
ANS Classic vs Reference
0,16
0,14
0,12
A4_Ref
A4_Ref
0,08
A2_Coating
A2_Coating
0,06
A3_Coating
A3_Coating
0,04
0,02
Time [s]
2300
2200
2100
2000
1900
1800
1700
1600
1500
1400
1300
1200
1100
900
1000
800
700
600
500
400
300
200
100
0
0
Friction koef.
0,1
Wear marks on counter surface after friction test
From right to left: Reference, ANS coating A2, ANS coating A3
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Load: 100 N
Ring: CrN PVD ring
Oil: SAE 30
Oil temperature: 20°C
0.12
COF (average)
0.1
0.08
0.06
ANS
0.04
Standard
0.02
0
0
50
100
150
200
Speed (RPM)
250
300
350
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Stroke: 24mm
Load: 8N
Velocities: 1Hz
Time: 10min
Nominal contact
pressure: 1.42 MPa
•10mm wide liner
samples
•Liner samples halfcoated,half-uncoated
•New twin land oil
control ring
COATED
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Project Wonaco2
Engine tribology 101
ANS Triboconditioning
Project focus and results
Summary
27
Triboconditioning can be used to reduce frictional
losses in heavy duty diesel engines
Good results in 10+ projects so far (Volvo, Scania,
Mahle, Federal Mogul, Gnutti, Ford, Atlas Copco
Secoroc, Tetra Pak, Hägglunds Drives, Bosch,
BodyCote, ...)
Wonaco2-projektet gave us a great opportunity to do
advanced research in the area of Triboconditioning
We will now continue our work to get the
triboconditioning method in production!
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EcoTrib - 2011
TLT - 2011
TAE - 2012
STLE - 2012
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Mattias Karls, +46 70 348 35 20
mattias.karls@appliednanosurfaces.com

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