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엔진부품을 위한 카본계 내마모 윤활코팅

엔진부품을 위한 카본계 내마모 윤활코팅. 2006. 5. 30. KIST- 현대자동차 협력 포럼 KIST 미래기술연구본부 이 광 렬. Contents. Brief Introduction to Diamond-like Carbon Coatings Applications of DLC to Automobile Parts DLC Research at KIST. Hard disk. Heart valve. What is DLC ?. Amorphous Solid Carbon Film

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엔진부품을 위한 카본계 내마모 윤활코팅

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  1. 엔진부품을 위한 카본계 내마모 윤활코팅 2006. 5. 30. KIST-현대자동차 협력 포럼 KIST 미래기술연구본부 이 광 렬

  2. Contents • Brief Introduction to Diamond-like Carbon Coatings • Applications of DLC to Automobile Parts • DLC Research at KIST

  3. Hard disk Heart valve What is DLC ? • Amorphous Solid Carbon Film • Mixture of sp1, sp2 and sp3 Hybridized Bonds • High Content of Hydrogen (20-60%) • Synonyms • Diamond-like Carbon • (Hydrogenated) amorphous carbon (a-C:H) • i-Carbon • Tetrahedral Amorphous Carbon

  4. Bond Structure of Carbon 1S2 2S22P2

  5. 2-D Analogy of Structure a-C:H ta-C

  6. Properties of Solid Carbon

  7. 경질코팅층의 내마모 윤활특성 마모도 마찰계수. DLC WC TiN CrN TiCN 2.0 1.6 1.2 0.8 0.4 (상대비교치) 0.2 0.4 0.6 0.8 1.0 Against steel ball, 50% RH, RT (Source : Nanotech Co. Ltd)

  8. CD/DVD Mold Form Die VCR Head Drum Spacer Tool Hard Disk & Slider Wrist Pin Digital VCR Tape Razor Blade Applications of DLC

  9. CarbofilmTM by Sorin Biomedica, Inc. Applications of DLC

  10. 1000 Dense Hydro- Carbon Dense Carbon 100 Impact Energy (eV) Polymer Like Carbon 10 Amorphous Carbon (sp2) 1 Plasma Polymers Carbon Source Hydrocarbon Source Deposition Methods Ion Source Energy Cold Substrate

  11. Ion Energy Distribution PACVD

  12. Examples of the Deposition Method

  13. Development of Diesel Engines • Diesel engines are designed with continuously increasing power densities since the introduction of HP-fuel injection systems (1993). • Power and torque of diesel engines increased at a much higher rate than gasoline engines. • Meetenvironmental laws and cost reduction requirements. Momentum development for typical 2 liter Petrol and Diesel engines over 35 years. (Source : Dr. Strondl @ Hauzer)

  14. Driving Force : Economy and Environment • Reduction of Energy Consumption • Reduction of friction • Reduction of Emission • Higher pressure fuel injection • Predictable wear of piston ring • Cost Reduction • Reduction of parts numbere.g. sliding bearing instead of needle bearing coated piston pin coated tappet • Wear Protection • Higher load per surface area

  15. camshaft tappets valves piston piston rings crankshaft Friction Loss in Engine (Source : Dr. Strondl @ Hauzer, 2005)

  16. Available Coatings at Present (Source : ICMCTF 2005 / 2006)

  17. Coating Technology for Automobile Engines (Source : Dr. Strondl @ Hauzer, 2005)

  18. Penetration Fraction of PVD (2006) • Diesel Pump 100% since 1994 • Crankshaft Bearing 100% since 1987 • Piston Ring 10% since 1993 • Valve train (Tappet) 2% since 2001 • Piston Pin 1% since 2002 • Gear < 1% since 2000

  19. Optimized to the application for minimum wear and power consumption Composition Multilayer structure Microstructure Demands in Automobile Applications • Low wear of Coated Part • Suppress abrasive wear • Suppress adhesive wear • Suppress fatigue wear • Low Wear on Counterpart • Low Coefficient of Friction

  20. Nanocomposite / Multilayer 5nm 5nm W-DLC by Hybrid Ion Plating (KIST) CrC/W-DLC Multilayer (Hauzer)

  21. Fuel Injection System Part: Diesel fuel injector and plunger Coating: a-C:H, W-C:H with metallic buffer Coating thickness >1 μm Benefit Wear resistance, preventing seizure 2000~3000bar Figure from Robert Bosch GmbH

  22. Unit Injection System (1.9TDI) • Technical Data • Engine power: 96 KW (130 PS) • Injection pressure: 2050 bar • Pressure power: 14.000 N • Advantages • Increased efficiency (lower friction) • Increased engine torque • Reduce energy consumption • Reduction of the CO2-emission Source: Volkswagen AG, Wolfsburg

  23. Valve Train (Source : Dr. Strondl @ Hauzer)

  24. Piston Ring - Sliding contact - Abrasive wear (also liner to be protected) - Temperature load Coating 200 µm hard Cr (galvanic) 30-40 µm CrN (PVD Arc) ~10 µm DLC (PACVD) / Me-DLC (PVD) (Source : KIST & DHI 1996)

  25. DLC Application by Nissan 日産自動車，水素フリーDLCコーティングによる摩擦低減技術を開発 日經 BP 2006/03/15 21:15 Compatibility with special lubricant of different additives (m = 0.07) 연말 실용화 목표

  26. Gears Full oil film lubrication  DLC has not shown a beneficial influence. Boundary lubrication(stopping/starting, severe load, temporary loss of lubricant)  DLC coatings can significantly reduce wear. Maximum load carrying capacity of gears can be increased by 10-40%. Coated spur gear

  27. Door Lock to reduce noise

  28. Coating Technology for Automobile Engines (Source : Dr. Strondl @ Hauzer, 2005)

  29. DLC Research @ KIST • Synthesis and Application of DLC Films • Control of structure and properties of DLC films • Modification of DLC films by third element addition • Nanoscale structure manipulation for novel functions • Tribo-chemical Aspect of DLC Films • Mechanical Properties of Thin DLC Films • Application technologies • Adhesion improvement • Coating layer optimization • Production process development http://diamond.kist.re.kr/DLC

  30. CD/DVD Mold Form Die VCR Head Drum Spacer Tool Hard Disk & Slider Wrist Pin Digital VCR Tape Razor Blade Applications of DLC

  31. Technology Transfer to Industry J&L Tech Co. Ltd Daewoo Electronics Co.

  32. Application to Top Ring Required Properties of Top Ring • Anti-scuffing • Wear Resistance • Low Friction Coefficient • Chemical Stability • Self Lubrication • Low Cost Schematics of Diesel Engine

  33. Deposition Method • 250KHz PACVD using CH4 at 200 mTorr • Cylinder Coating Technology (analogy to VCR Head Drums) • Buffer Layer Design for Optimum Adhesion ~10mm Thick Films

  34. sliding direction piston ring cylinder liner (boron cast iron) Reciprocal Tribometer (Plint 77)

  35. Anti-scuffing Property of Piston Rings Test condition : load :200N, marginal lub. condition 250 200 150 Time to failure(hour) 100 50 0 Cr WS2-1 WA2-2 GN PVD DLC

  36. Wear Test under Dry Lubrication Conditions

  37. Result of Dynamo Test (900h) Hard Cr Coated Ring DLC coated Ring Before Test Before Test After Test After test

  38. Hard Cr Coated Piston Ring DLC/Cr Coated Piston Ring 6.5mm 100mm Before Test Before Test 5.3mm After Test After Test

  39. Adhesion In most cases, film adhesion is more important than the mechanical properties. Environmental Effects Compatibility with new lubricants Adhesion degradation in aqueous environment Tribochemical Reaction for Fundamentals In-situ observation of the contact surfaces Third element effect Multilayer effect Market Penetration Based on the advanced technology Issues in Carbon Base Coatings

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