Direct coating

Transcription

Direct coating
Innovation in Motion
Company
Speaker
Miba Coating Group
Eitzinger Günter
Chief Engineer
No powertrain without Miba Technology
Divisions at a Glance
Miba 5000 Employees worldwide
Bearing
Group
Sinter
Group
Friction
Group
Innovation in Motion
New
Technologie Coating
s Group
Group
Innovation in Motion
Direct coating of conrods and bushings
substitution of sliding bearings
MIBA Coating Group
Friction losses example Daimler
Source:
Motorsymposium 2012 Vienna
Innovation in Motion
Bearingless Conrod – Direct coating
• Increased load ability
• Smaller bearings
• Less hydrodynamic friction
• Smaller tolerances
• Reduced Weight
• Increased stiffness
• Smaller engine
• Less oil consumption
• Smaller oil pump
Innovation in Motion
Example picture
Innovation in Motion
Basic Technology
Miba Invention:
The Cylindrical Cathode
Advantage: Uniform Layer
also for thick layers and
large bearings
eAr+
Sputtering Process:
eee- Cathode
(ca. 600V)
ee-
1.  Argon Ions Bombard the
Cathode
2.  Al and Sn Atoms are
released by the kinetic
energy of the Ions
3.  Freed Atoms are moving
through the cylindrical
space and form the
layer of the bearing
Innovation in Motion
Concept and Machinery
Sputtering
Coating 1 Ni
Sputtering
Coating 2
Loading
Ion Etching
Cleaning
View into Coating
Chamber
Star Concept:
Diameter:
30 – 190
Batch Concept:
190mm to 350 mm
Miba Sputter Bearing AlSnX
Innovation in Motion
4  Description:
AlSn20 layer applied using
a Miba-developed PVD sputtering process
4  Application:
High performance engines with high power density
for high speed ferries, locomotives, ships
and automotive applications
4  Characteristics:
Extraordinary high load carrying capability, good
tribological properties and superior wear resistance
Roll bonded
AlSn
Sputtered
AlSn
Innovation in Motion
Hydro-dynamic Bearing Type Performance
Kleinster Schmierspalt [µm]
min oilfilm thickness [µm]
0.8
0.9
1
Bauarten / Bearing T ypes
Prototype
Standard
Development
Application Area Sputter .
Application Area Tri-Metal
.
Sputter NEW
Sputter Bearing
Synthetic OL
PnSnCu PRO
Rillenlager
SnSb PRO
2
3
Outstanding
Hydrodynamic
Performance
Tri-Metal Bearing
BIAL AlSn25
AlSn20
BIAL AlSn20
4
AlSn40
5
1000
1500
Application Area Bi-Metal
2000
2500
3000
3500
4000
.
4500
Schmierfilmspitzendruck [bar]
max Oilfilm Pressure [bar]
5000
5500
Sputter Coating Properties
Innovation in Motion
New Al- based Alloy:
•  Sn content ~20 wt. %
•  Al - Matrix
Alloy Composition:
Sputter - Layer
Ni - Layer
Sn 20 %
Bronze
Cu 2 %
Al 78 %
References:
Cross Section:
Hardness: 80 - 120 HV
Passenger Car: All European Common Rail Diesel Engines
Heavy Duty Truck: DC, MAN, DAF …
High Speed: mtu, MWM - Deutz, CAT …
Medium Speed, GAS: GE - Jenbacher …
Improved Sputtered Overlay Properties
Innovation in Motion
New Al- based Alloy:
• 
Sn content ~25 wt. %
• 
Near eutectic AlSi- matrix
New Alloy Composition:
Sputter - Layer
Ni - Layer
Al 67,5%
Bronze
Si 7,5%
Sn 25,0%
Cross Section:
Production parameters:
Ø Similar to AlSn20Cu
Grain size: Sn < 1 µm
Si << Sn
Hardness: 130 - 150 HV
Innovation in Motion
Relative Bearing Type Performance
Best Overall Performance of
all known Bearing Types
Best Overall Performance in High
Loaded Applications with Dirt
Shock and Dirt Contamination
Film Thickness
Fatigue
80
Bearing Types
Sputter AlSnSi
Sputter
Std. Tri-Metal
60
Emergency
40
Test Results after 15 hours running time
Dirt Contamination Test - - 100% Oil - Test runs without oilfilter
20
0
20
40
60
80
Cl - Corrosion
100
80
Dirt volume 60
Survival Rate
[%]
40
Wear
20
S - Corrosion
Cavitation
0
Trimetal Bearing
22 µm Overlay
Trimetal Bearing
3 µm Overlay
Rillenlager
Sputtered Bearing
14 µm Overlay
Bearingless Conrod – Direct coating
1.  Layer
2.  Layer
Innovation in Motion
20 - 60 µm AlSn20Cu
5 - 20 µm Synthec®Pro - Sliding Lacquer
Bearingless Conrod – Direct coating
Innovation in Motion
„Lemmon shape“
Compensate deformations
Caused from masses of inertia
Taylor made Sputter Machines
Capacity and Capability:
•  Diameter Range 30 to 350 mm
•  AlSn20, AlSn25 Si
•  More than 50 Million coated bearings
Innovation in Motion
Sliding lacquers: Synthec™Pro
Innovation in Motion
Engine :
EA 888 Audi 4 Cylinder Gasoline (World engine) Integrated Mass Balancer System
Engine Start Stop – reduced friction , improved emergency behavior of the system
Rotational speed :
max. 14000 rpm
Max. Torque:
max. 60 Nm
One Radial- and two integrated axial bearings on a net shape sintered part
Detail Synthec®Pro on Sintermaterial
Innovation in Motion
Typical structure of a 20 µm Synthec®Pro overlay on a powdermetal part
Test arrangement
Ring on disc tests SynthecPro®
(oil jar not shown)
• 100Cr6 Ring
• 1.2379 disc Ø40mm 58+2HRC coated,
submerged in Shell Helix Ultra 5W30
• Specific load 1-3-5MPa
• Temperature: 55°C
Innovation in Motion
Innovation in Motion
COF versus Load of Synthec Pro
®
100Cr6 ring against SynthecPro on 1.2379 hardened
under Shell Helix Ultra 5W30@55°C
cycles [1]
0
200.000
400.000
600.000
800.000
1.000.000 1.200.000 1.400.000 1.600.000
0,2
6
0,18
friction coefficient
0,14
4
0,12
0,1
3
0,08
2
0,06
0,04
1
0,02
0
0
10000
20000
30000
40000
50000
sliding distance [m]
60000
70000
80000
0
90000
specific load
5
0,16
friction coefficient [-]
specific load [MPa]
Synthec®Pro on AlSi9Cu3 Alloy
Innovation in Motion
Cross-section from a
21 µm SynthecPro
Layer on an aluminium
alloy.
Nearly all materials
Possible.
Application examples of Synthec Pro
Innovation in Motion
sliding bearings
split gears
piston skirt
sprockets
bearing block
intermediate gears
Synthec Pro Properties
Innovation in Motion
Performance Attributes
• 
• 
• 
• 
• 
• 
• 
• 
• 
Temperature range in applications (-50 up to 250°C)
Superior wear behavior
COF 0,03 – 0,08 (mixed friction area)
Special adaptive behavior during running in time
Due too solid lubricants extremely good emergency behavior
Corrosion resistance
Environmental friendly
Potential for weight reduction
Potential for cost reduction
Direct coating – Substitution of bearings
Innovation in Motion
Advantages:
•  Reduced weight
•  Reduced space
•  Smaller overall dimensions
•  Smaller width or diameter
•  Increased loadability
•  Degreased friction losses also in hydrodynamic condition
•  Enabler for use of low viscosity fluids >low friction
•  Less tolerances
•  Less assembly efforts
Contact
Miba Coating Group
Günter Eitzinger
Head of Advanced Engineering
Dr. Mitterbauer-Str. 3
A-4655 Vorchdorf, Austria
T +43/7614/6541-8200
F+43/7614/6541-8400
M +43/664/8560418
www.miba.com
guenter.eitzinger@miba.com
Innovation in Motion

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