Quality Designed Twin Wire Arc Spraying of Aluminum Bores

• Published in: Journal of thermal spray technology Vol. 24; no. 1-2; pp. 63 - 74
• Main Authors: König, Johannes, Lahres, Michael, Methner, Oliver
• Format: Journal Article
• Language: English
• Published: Boston Springer US 01.01.2015
• Subjects: Analytical Chemistry; Characterization and Evaluation of Materials; Chemistry and Materials Science; Corrosion and Coatings; Machines; Manufacturing; Materials Science; Peer Reviewed; Processes; Surfaces and Interfaces; Thin Films; Tribology; liner coating; spray spot; deposition simulation; optimization; spray distance; twin wire arc spraying
• ISSN: 1059-9630; 1544-1016
• DOI: 10.1007/s11666-014-0170-6

After 125 years of development in combustion engines, the attractiveness of these powerplants still gains a great deal of attention. The efficiency of engines has been increased continuously through numerous innovations during the last years. Especially in the field of motor engineering, consequent friction optimization leads to cost-effective fuel consumption advantages and a CO 2 reduction. This is the motivation and adjusting lever of NANOSLIDE ® from Mercedes-Benz. The twin wire arc-spraying process of the aluminum bore creates a thin, iron-carbon-alloyed coating which is surface-finished through honing. Due to the continuous development in engines, the coating strategies must be adapted in parallel to achieve a quality-conformed coating result. The most important factors to this end are the controlled indemnification of a minimal coating thickness and a homogeneous coating deposition of the complete bore. A specific system enables the measuring and adjusting of the part and the central plunging of the coating torch into the bore to achieve a homogeneous coating thickness. Before and after measurement of the bore diameter enables conclusions about the coating thickness. A software tool specifically developed for coating deposition can transfer this information to a model that predicts the coating deposition as a function of the coating strategy.