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2021
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Key process of cylinder liner-free technology | coating honing
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Automotive engine linerless technology originated in Europe. It uses thermal spraying technology to spray a layer of wear-resistant coating on the inner wall of the aluminum engine cylinder to replace the traditional cast iron cylinder liner. It can not only reduce the weight and fuel consumption of the engine, but also significantly Reduce engine friction and improve engine performance.
Automotive engine linerless technology originated in Europe. It uses thermal spraying technology to spray a layer of wear-resistant coating on the inner wall of the aluminum engine cylinder to replace the traditional cast iron cylinder liner. It can not only reduce the weight and fuel consumption of the engine, but also significantly Reduce engine friction and improve engine performance.
After the cylinder block is sprayed, the final machining of the coating is very important. The coating must be honed to ensure that the cylinder reaches the correct diameter, roundness and surface roughness specified. A well-known European thermal spray company has made fine adjustments to the recommended technical specifications for the coating surface after honing based on the results of oil and fuel consumption reduction obtained from engine tests.
After rough honing and fine honing, the inner surface of the cylinder bore can reach the mirror finish, as shown in Figure 2. Compared with the honing of the traditional cast iron cylinder liner, the surface after coating honing is porous instead of reticular structure. Figure 3a is the surface microstructure of the traditional cast iron cylinder liner after honing, and Figure 3b is the microstructure after coating honing.
It is precisely because of the porous structure of the coating surface that the smoothness of the coating surface can be reduced to 25%. This is one of the reasons why this technology can save a lot of engine oil. The smooth, rounded holes also reduce the area of engine oil exposed to the combustion chamber and piston rings, reducing the tangential force of the oil scraper ring, allowing the piston rings to enter a fluid dynamic state faster, significantly reducing friction. The working diagram is shown in Figure 4. Smaller engine friction means lower frictional heat energy consumption, reduced engine blowby and fuel consumption, and ensures the highest operating reliability.
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