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Ceramic Coating for Aluminum Engine and Components
Technical Paper
91A105
Sector:
Language:
English
Abstract
The trend toward lighter vehicles for improved performance has
recently introduced the use of aluminum and plastic materials for
vehicle bodies and drive trains. In particular, the aluminum alloy
block foar engine application is certain to reappear. The soft
aluminum cylinder liner will require additional treatment before
acceptance. Three possible approaches appear to solve the aluminum
cylinder liner dilemma. These approaches are: 1) use of high
silicon aluminum such as the 390 aluminum; 2) insert or cast steel
liners into the aluminum engine block; and 3) ceramic coat the low
cost standard aluminum engine block. Each has known advantages and
disadvantages. It is the purpose of this paper to present the
merits of option 3, the ceramic coated aluminum cylinder bore, from
the standpoint of low weight, cost, and tribological
effectiveness.
The advantages of approaches 1) and 2) are obvious. High
temperature after treatment of the ceramic engine components is not
required. Aluminum properties are such that one must carefully
observe changes in physical properties of aluminum such as creep,
aging, stress/strain and other important properties dependent upon
temperature. Therefore, a ceramic coating possessing low curing
temperature is highly desirable. A low temperature organo-metallic
phosphate (CMP) coating developed recently for aluminum alloy
substrates is expected to meet requirements of lowered cost and
improved effectiveness for engine applications.
Engine tests were conducted to determine the effectiveness of
this ceramic composite coating. The aluminum engine block of a
small bore single cylinder diesel engine was ceramic composite
coated and laboratory rig tested. Preliminary test data has shown
the aluminum composite coating has performed well. Durability tests
are currently underway to demonstrate the viability of these
ceramic coated aluminum components for tribology and insulation of
future engine components.
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