Powertrain Systems
February
2014
Property of Comau - Duplication prohibited
THERMAL SPRAY LINERS POWERTRAIN
February
2014
Powertrain Systems
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2 2
1998 1 Car …now in 2014
16 Cars and Growing
Efficiency
Performance
February
2014
Powertrain Systems
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3
Thermal Spray Liners
1. Advantages of Monolithic Block with a
coating
•
•
•
•
•
Cost
Weight Reduction
Improved Durability
Flexible Manufacturing
Packaging
2. Improvement of Thermodynamics
•NVH, Knock & Friction Reduction
•Fuel Economy/Emissions
•Packaging
•No Gaps, Low Heat (Q) Capacity
3. Improvement of Tribology
•Friction Reduction
•Fuel Economy
•Improved Durability
•Start Stop Enabler
•Emissions
* As compared to cast-in Cast Iron and HiSilicon Liners
February
2014
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Challenges – Where’s the
Energy Going
Source: Mazda, CAR 12/12
February
2014
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3. PTWA Friction Reduction
PTWA offers potential for reduced friction by allowing smoother honing
while maintaining oil retention due to thermal spray porosity
SIGMA 1.6l Liner vs.. PTWA
Ford/FSI SAE paper 2008
February
2014
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3. Friction Reduction
Measured
Chrysler D.O.E. Development Engine,
Chrysler/DOE Review 2011
SIGMA 1.6l Liner vs.. PTWA
Ford/FSI SAE paper 2008
February
2014
Powertrain Systems
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7
THERMAL SPRAY
TECHNOLOGY
February
2014
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PTWA
Key Features
Plasma Transferred Wire Arc
Pros
Consistent Porosity
Process Stability and Repeatability
High Wire Capacity
Ability to coat with large range of
wire products
Dust K-factor of zero
Customer Concerns
1st
February
2014
Automotive Production: 2007 Nissan w/FSI
2010 Ford
Using non-mixed Hydrogen gas
(addressed)
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SURFACE ROUGHENING
TECHNOLOGIES
February
2014
Powertrain Systems
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1010
Surface Prep: Background
Comparison of Grit Blasted To Water Jet Prepared
Water Jet:
Grit Blast:
February
2014

Grit must follow the angle of reflection.

Follows fluid stream dynamics.

Mechanical Impact and Wear of the Substrate.

Erosion of the substrate.

Requires aggressive cleaning and drying.

Drying only.
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Surface Prep: Background
Mechanical Surface Fine Bore Finishing
Nissan (Production)
• Cuts and breaks threaded
form
Tool Travel
Deformed Square Groove
Threaded form
• Cut then plastically deform
fin of substrate
Targetted form
• Concentric grooves with
mechanical forging
Braunshweig (Limited
Production)
• Cuts dove tail in threaded
form
Key Characteristics:
• Substrate Quality ( can handle porosity <1.25mm)
• Surface complexity and Roughness
• Process Stability and Measurability
• Surface must be clean and dry, not required by dry or MQL
machining
February
2014
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COATING CHARACTERISTICS
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2014
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A Basic PTWA Coating
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February
2014
Low Carbon steel wire
Composition: 0.1C, 0.6Mn,0.045P, 0.04S Fe Balance
Low Cost Wire
Compatible with conventional Piston Ring Packs
Porosity is approx. 2%
Wuestite and Iron matrix
• The combination of Wuestite(FeO) and porosity reduce the friction and
wear of the honed surface
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THERMAL SPRAY LINER
IMPLEMENTATION
February
2014
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Keys to Successful
Implementation
• Processing
Configuration
Linerless
Casting
Heat
Treat
• Casting Process
• Type
• Casting
Quality
• Block Design
February
2014
Super
Cubing
Machining
Crank Bore
Leak Test /
Impregnation
Boring –
Mech Prep
Final
Machining
Honing
Washing
• Coating Morphology
• Coating Thickness
• Overspray
Processing Configuration
Depending on the integration
type:
• Greenfield
• Brownfield
Need to balance your goals of:
• Manufacturing simplicity
• Engine Performance
• Cost
• Investment
Recommended implementation:
• Fine Boring with Surface
Preparation
• Coating
• Finish Boring with Rough Hone
Thermal
Spray
• Coating Morphology
• Coating Thickness
• Overspray
• Deposition
• Surface Roughness
• Adhesion
• Final Coating
Roughness
• Cleanliness
• Adhesion
• Coating
Quality
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February
2014
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SMARTspray-PTWA
Production Cell
Fully Integrated Cell on a Common Chassis
Robot
controller
Load/unload
robot or robot
gantry load
Gas panel
2 door
elec.
enclosure
*patent pending air flow
Torch power
supply
“L” shaped automatic
doors
February
2014
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SMARTspray Liner System
Value Propositions :
●
Minimum foot print installation : 15 m²
●
H2On: On board hydrogen generation
●
High deposition efficiency
●
Dual Spindle and output capability
●
Low operating cost
●
Patent Pending bore coating control
process
●
On the floor bulk feed stock
●
Low as-sprayed coating roughness
●
Patent pending targetted roughening
February
2014
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Support Capabilities
 Prototyping

Engineering Design support for Adaptation of Liner Systems
• 50+ years of broad Thermal Liner Coating Experience

Prototype
• Currently capable of handling up to 900lbs and bores down to 67mm diameter,
machining and hone supply base
• 4th Quarter 2013: In-house surface roughening, and bores down to 37mm, Autolab with
functioning production cell
 Production Development

Comau can be your single source for a full block production system (Machining, Material
Handling, Inspection, Surface Preparation, Coating and Honing, Cleaning, Assembly and
Test) to just a single equipment source(CNCs, Coating cells, Assembly centers, and Test
stands)
 Customer Support
February
2014

Thermal Spray Core group is located in Royal Oak, Mi

Support Staff in Shanghai, China and Turin, Italy.
• 4th Quarter Additional Support group in Mexico City, Mexico
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COMAU S.p.A.
Via Rivalta, 30
10095 GRUGLIASCO (TO)
ITALY
www.comau.com
February
2014
Powertrain Systems
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of Comau
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