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Friction and wear reduction in heavy-duty diesel powertrains

Friction and wear reduction in heavy-duty diesel powertrains. Project Wonaco2 - Tribodays , Örnsköldsvik - 2012-11-07. Agenda. Project Wonaco2 Engine tribology 101 ANS Triboconditioning Project focus and results Summary. Project Wonaco2.

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Friction and wear reduction in heavy-duty diesel powertrains

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  1. Friction and wear reduction inheavy-duty diesel powertrains Project Wonaco2 - Tribodays, Örnsköldsvik - 2012-11-07

  2. Agenda • Project Wonaco2 • Engine tribology 101 • ANS Triboconditioning • Project focus and results • Summary

  3. Project Wonaco2 • 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

  4. Agenda • Project Wonaco2 • Engine tribology 101 • ANS Triboconditioning • Project focus and results • Summary

  5. Emission legislation

  6. Friction losses in an engine Heat losses (exhaust, cooling, etc.) 60% Friction losses 15% Useful kinetic energy 25% * Auxiliary systems, injection pump, etc. 15% of all energy supplied to an engine is lost due to friction

  7. Agenda • Project Wonaco2 • Engine tribology 101 • ANS Triboconditioning • Project focus and results • Summary

  8. Triboconditioning Process Fluid Tool Steel surface TEM-image of the coating

  9. Application areas and usage APPLICATIONS USAGE CORE METHOD Turning F Tool Piston pins Cylinders v Crankshafts Rockdrills Honing Steel surface Turbine shafts Hydraulic rods Bearings Camshafts

  10. Effect from Triboconditioning • Controlled Running-in • Peaks removed (Rpk reduced) • Nano-composite TRIBO-layer to reduce friction and wear Original surface Triboconditionedsurface Triboconditioning improves surface finish and deposits a low-friction tribolayer in one process step

  11. Tribofilm up close (FIB/TEM) Protective layer from sample preparation Amorphous deposited film 20-100 nm Steel substrate

  12. Stribeck effect Lowered boundary frictiondue to easily shearednano-composite coating Surface layer prevents asperity-asperity contactsand the coating improves oil affinity,hence the shift to the left of the curve

  13. Agenda • Project Wonaco2 • Engine tribology 101 • ANS Triboconditioning • Project focus and results • Summary

  14. Research focus Wonaco2 • 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?

  15. Triboconditioning in Action Triboconditioning of shafts Triboconditioning of cylinder liners

  16. Scania roller tappet shaft Roller tapper shaft, Triboconditioned bearing positions Schematicpicture of Scania valve system

  17. Scania roller tapper shafts Results – Friction & Wear Wear marks on countersurface after friction test above From left to right: ANS triboconditioning, Reference 1, Reference 2 Frictionreading; ANS triboconditioning vs Reference

  18. Volvo rocker arm shafts

  19. Volvo Rocker Arm Shaft Results – Friction & Wear Wear marks on counter surface after friction test From right to left: Reference, ANS coating A2, ANS coating A3

  20. Cylinder liners

  21. Why are cylinder liners special?

  22. Effect from Triboconditioning

  23. Smoother plateaus

  24. Reduced RPK Coated cylinder liner

  25. Friction reduction - liners • Load: 100 N • Ring: CrN PVD ring • Oil: SAE 30 • Oil temperature: 20°C

  26. Halftreated segment (HH) COATED • Stroke: 24mm • Load: 8N • Velocities: 1Hz • Time: 10min • Nominal contact pressure: 1.42 MPa • 10mm wide liner samples • Liner sampleshalf-coated,half-uncoated • New twin land oilcontrol ring

  27. Agenda • Project Wonaco2 • Engine tribology 101 • ANS Triboconditioning • Project focus and results • Summary

  28. Summary • 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!

  29. Publishedpapers EcoTrib - 2011 STLE - 2012 TLT - 2011 TAE - 2012

  30. Mattias Karls, +46 70 348 35 20 mattias.karls@appliednanosurfaces.com

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