No powertrain without Miba Technology

Company
Speaker
Miba Coating Group
Eitzinger Günter
Chief Engineer
No powertrain without Miba Technology
TT-KC, TT-HS
CONFIDENTIAL
Coatings Examples Super low-friction DLC – Bearingless
Conrod – Substitution of bushings –Silent Gears - Spacecoat
1) MIBA Coating Group, 2) University of Leoben, 3) WZL Aachen
Teer Coatings Ltd, Miba Coating Group
www.miba.com
TT-KC, TT-HS
CONFIDENTIAL
Innovation in Motion
Agenda
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Motivation
High Temperature DLC
Replacement of bearings and bushings – Conrod
Adaptive Coatings on gears Spacecoat Coating
Summary
Innovation in Motion
Motivation
Source: A.Merkle, M.Werner, Technical University of Munich, Institute of Combustion engines ©2008-2009
Innovation in Motion
Diamond like carbon (DLC) Classification
Innovation in Motion
High Temperature DLC Deposition
Deposition parameters:
•Unbalanced magnetron sputtering
•Ar-plasma
•Temperature: < 200°C
•Rotation: 8-10 rpm
•Bias: - 60 V / pulsed 50 kHz
•Deposition Pressure: 0.3-0.4 Pa
•Substrates: M42 tool steel, Si (100)
Coating architecture
Graphit-iC layer
Ramp: 100 at% Cr → 100 at% C
Cr-Interlayer
Substrate
 2 µm
 0.5 µm
 0.1 µm
Innovation in Motion
Depth [µm]
Friction coefficient µ
Graphit-iC™HT (Hardness ~1900HV)
3D View
Sliding distance [m]
Ball-on-Disc Test:
 Applied Load: 10N @ 325°C
 Friction coefficient ~ 0,05
 Very low specific wear
1.2 mm
0.9mm
Innovation in Motion
100Cr6 Ring-on-Disc, 2MPa, 120°C
Oil: Shell Helix Ultra (5W30)
coated disc
uncoated disc
sliding speed
Coated / Uncoated = -30%
Innovation in Motion
Possible application
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Piston Pins
Piston Skirt
Piston Ring
Liner
Tappets
Valves
Cam
Conrod
Camshafts
Turbocharger components
Innovation in Motion
Bearingless Conrod – Direct coating
1.
2.
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5.
6.
7.
8.
9.
Increased load ability
Smaller bearings
Less hydrodynamic friction
Smaller tolerances
Reduced Weight
Increased stiffness
Smaller engine
Less oil consumption
Smaller oil pump
Example picture
Innovation in Motion
Bearingless Conrod – Direct coating
1. Layer
2. Layer
AlSn20Cu PVD
Synthec®Pro
High Loadability
Running in
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Examples of Sputter Machines
Capacity and Capability:
Millions of Parts All Metals and alloys, Nitrides…
Innovation in Motion
Possible App. - Post Magnetron Technology
Also possible to coat liners with CrN and DLC
Friction reduction
Innovation in Motion
Hydro-dynamic Bearing Performance
Kleinster Schmierspalt [µm]
min oilfilm thickness [µm]
0.8
0.9
1
Bauarten / Bearing Types
Prototype
Standard
Development
Sputter NEW
Application Area Sputter .
Sputter Bearing
Application Area Tri-Metal .
2
Synthetic OL
PnSnCu PRO
Rillenlager
SnSb PRO
3
Tri-Metal Bearing
BIAL AlSn25
AlSn20
BIAL AlSn20
4
AlSn40
5
1000 1500
Outstanding
Hydrodynamic
Performance
Application Area Bi-Metal .
2000
2500
3000
3500 4000
4500 5000
Schmierfilmspitzendruck [bar]
max Oilfilm Pressure [bar]
5500
Innovation in Motion
Sliding lacquers: Synthec™Pro
Engine : EA 888 Audi 4 Cylinder Gasoline (World engine)
Integrated Mass Balancer System
Reason: Engine Start Stop –coating reduce friction and increase emergency
behaviour 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
Innovation in Motion
Detail Synthec®Pro on Sintermaterial
Innovation in Motion
Test results 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]
Innovation in Motion
Application examples of Synthec Pro
sliding bearings
split gears
piston skirt
sprockets
bearing block
intermediate gears
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Synthec Pro Properties
Performance Attributes
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Very wide temperature range in applications (-50 up to 300° C)
Superior wear resistance
Corrosion resistance
Adaptive behaviour
Avoidance of frictional corrosion
Environmental friendly
Potential for weight reduction
Potential for cost reduction
Innovation in Motion
Silent Gears
Cr/Ag or CuSnC
coating system:
(Immiscible; Hardness adjustable
between 200 and 1000HV)
4 layers visible
Coating thickness: 16µm
Interlayer thickness: 1,5-2 µm
Innovation in Motion
Results
NVH Test Rig
 2 servo engines
 adjustable axis
distance and
backlash
 0 – 6000 rpm
 0 – 20 Nm oscillating
torque
 up to 10 Hz
Innovation in Motion
Uncoated vs. Coated gear
10dB Differenz
Innovation in Motion
Summary
• Reducing CO2 emission is one of the top priorities for the
automotive industry and us
• Coatings technology is a key for reduction of friction and
enabler for new technical solutions
Thank you for your attention.
Innovation in Motion
Contact
Miba Coating Group
Günter Eitzinger
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