Friction and wear reduction in heavy-duty diesel powertrains

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

Project Wonaco2 Engine tribology 101 ANS Triboconditioning Project focus and results Summary 2

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 3

Project Wonaco2 Engine tribology 101 ANS Triboconditioning Project focus and results Summary 4

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Friction losses Heat losses (exhaust, cooling, etc.) 60% Friction losses 15% Useful kinetic energy 25% 5% 20% 15% 60%

* Auxiliary systems, injection pump, etc.

15% of all energy supplied to an engine is lost due to friction

Piston assembly Crank train Valve train Other* 6

Project Wonaco2 Engine tribology 101 ANS Triboconditioning Project focus and results Summary 7

Tool Steel surface

TEM-image of the coating

Process Fluid

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CORE METHOD F Tool Steel surface v USAGE Turning Honing APPLICATIONS

Cylinders Piston pins Crankshafts Rockdrills Hydraulic rods Turbine shafts Bearings Camshafts 9

Original surface

Controlled Running-in Peaks removed (R pk reduced) Nano-composite TRIBO-layer to reduce friction and wear

Triboconditioned surface Triboconditioning improves surface finish and deposits a low-friction tribolayer in one process step

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Amorphous deposited film 20-100 nm

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Lowered boundary friction due to easily sheared nano-composite coating Surface layer prevents asperity-asperity contacts and the coating improves oil affinity, hence the shift to the left of the curve 12

Project Wonaco2 Engine tribology 101 ANS Triboconditioning Project focus and results Summary 13

• • • • • 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?

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Schematic picture of Scania valve system

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Results – Friction & Wear

Rocker Arm Shaft "ANS3"

0,15 0,1 0,05 0 Time [s]

Friction reading; ANS triboconditioning vs Reference

ANS3 Ref1 ANS3 Ref2 ANS3 Coating

Wear marks on counter surface after friction test above From left to right: ANS triboconditioning, Reference 1, Reference 2

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0,06 0,04 0,02 0 0,16 0,14 0,12 0,1 0,08 Results – Friction & Wear

Volvo Rocker Arm Shaft "1"

ANS Classic vs Reference

Time [s]

A4_Ref A4_Ref A2_Coating A2_Coating A3_Coating A3_Coating

Wear marks on counter surface after friction test From right to left: Reference, ANS coating A2, ANS coating A3

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Load: 100 N Ring: CrN PVD ring Oil: SAE 30 Oil temperature: 20°C 0,12 0,1 0,08 0,06 0,04 0,02 0 0 50 100 150 200

Speed (RPM)

250 300 350 ANS Standard 25

Stroke: 24mm Load: 8N Velocities: 1Hz Time: 10min

Nominal contact

pressure: 1.42 MPa • 10mm wide liner samples • Liner samples half coated,half-uncoated • New twin land oil control ring COATED 26

Project Wonaco2 Engine tribology 101 ANS Triboconditioning Project focus and results Summary 27

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!

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EcoTrib - 2011 TLT - 2011 TAE - 2012 STLE - 2012 29

Mattias Karls, +46 70 348 35 20 [email protected]