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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

Friction and wear reduction inheavy-duty diesel powertrains

Project Wonaco2 - Tribodays, Örnsköldsvik - 2012-11-07

agenda
Agenda
  • Project Wonaco2
  • Engine tribology 101
  • ANS Triboconditioning
  • Project focus and results
  • Summary
project wonaco2
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
agenda1
Agenda
  • Project Wonaco2
  • Engine tribology 101
  • ANS Triboconditioning
  • Project focus and results
  • Summary
friction losses in an engine
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

agenda2
Agenda
  • Project Wonaco2
  • Engine tribology 101
  • ANS Triboconditioning
  • Project focus and results
  • Summary
triboconditioning
Triboconditioning

Process

Fluid

Tool

Steel surface

TEM-image of the coating

application areas and usage
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

effect from triboconditioning
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

tribofilm up close fib tem
Tribofilm up close (FIB/TEM)

Protective layer from sample preparation

Amorphous

deposited film

20-100 nm

Steel substrate

stribeck effect
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

agenda3
Agenda
  • Project Wonaco2
  • Engine tribology 101
  • ANS Triboconditioning
  • Project focus and results
  • Summary
research focus wonaco2
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?

triboconditioning in action
Triboconditioning in Action

Triboconditioning of shafts

Triboconditioning of cylinder liners

scania roller tappet shaft
Scania roller tappet shaft

Roller tapper shaft, Triboconditioned bearing positions

Schematicpicture of Scania valve system

scania roller tapper shafts
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

volvo rocker arm shaft
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

reduced r pk
Reduced RPK

Coated cylinder liner

friction reduction liners
Friction reduction - liners
  • Load: 100 N
  • Ring: CrN PVD ring
  • Oil: SAE 30
  • Oil temperature: 20°C
half treated segment hh
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
agenda4
Agenda
  • Project Wonaco2
  • Engine tribology 101
  • ANS Triboconditioning
  • Project focus and results
  • Summary
summary
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!
published papers
Publishedpapers

EcoTrib - 2011

STLE - 2012

TLT - 2011

TAE - 2012

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

mattias.karls@appliednanosurfaces.com