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Development of Novel Fe-Based Coating Systems for Internal Combustion Engines

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Abstract

Nowadays, combustion engines are the most common way to power vehicles. Thereby, losses occur due to cooling, exhaust gas and friction. With regard to frictional losses, highest potentials for optimization can be found in the tribological system of the inner surface of combustion chamber and piston ring. Besides friction, corrosive stress increases, e.g., due to utilization of exhaust gas recovery. In order to save energy, reduce emissions and enhance the life span of combustion engines, the demand for innovative coating material systems, especially for the inner surface of combustion chamber, increases. This study focuses on the development of innovative iron-based coating materials for the combustion chamber. As a first step, the plasma transferred wire arc and rotating single wire arc (RSW) technologies were compared using 0.8% C-steel as a reference. Subsequently, RSW was used for coating deposition using an innovative iron-based feedstock material. In order to improve wear and corrosion resistance, boron and chromium were added to the feedstock material. After deposition, different honing topographies were manufactured and compared under tribological load. Furthermore, electrochemical corrosion tests were conducted using an electrolyte simulating the exhaust gas concentrate. Especially with regard to corrosion, the novel coating system FeCrBMn showed promising results.

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Acknowledgments

The work in this paper is performed in the context of the research project “Entwicklung eines Innenbeschichtungsprozesses zur Herstellung korrosionsbeständiger und reibverlustmindernder Eisenbasisschichten für Zylinderlaufbahnen” (KF2757705SU4). This project is funded by the German Federal Ministry of Economics and Technology (BMWi) according to a decision of the German Federal Parliament.

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Authors and Affiliations

  1. Surface Engineering Institute, RWTH Aachen University, Aachen, Germany

    K. Bobzin, M. Öte & T. Königstein

  2. Technical University of Braunschweig, Institute of Machine Tools and Production Technology, Brunswick, Germany

    K. Dröder, H.-W. Hoffmeister & G. Mahlfeld

  3. GTV Verschleißschutz GmbH, Luckenbach, Germany

    T. Schläfer

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  1. K. Bobzin
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  2. M. Öte
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  5. H.-W. Hoffmeister
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  6. G. Mahlfeld
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  7. T. Schläfer
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Correspondence to T. Königstein.

Additional information

This article is an invited paper selected from presentations at the 2017 International Thermal Spray Conference, held on June 7-9, 2017, in Düsseldorf, Germany, that has been expanded from the original presentation.

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Bobzin, K., Öte, M., Königstein, T. et al. Development of Novel Fe-Based Coating Systems for Internal Combustion Engines. J Therm Spray Tech 27, 736–745 (2018). https://doi.org/10.1007/s11666-018-0705-3

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  • DOI: https://doi.org/10.1007/s11666-018-0705-3

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