【作者】

Bernd Distler,Peter Ernst

【摘要】

论文已在中国上海举行的2013年CIMAC大会上发表。论文的版权归CIMAC所有。 Rising fuel prices and more stringent requirements in the field of exhaust emissions, such as nitrogen oxides, particulate matter and carbon dioxide are significantly increasing the pressure on the manufacturers of internal combustion engines of all categories to find, evaluate and apply technologies that contribute to a reduction in these emissions. As a result, interest in cylinder inner diameter surface coatings has risen considerably in the last three to four years, and particularly in the SUMEBore® coating solution from Sulzer Metco. Such coatings are applied by a powder-based atmospheric plasma spray (APS) process. The APS coating process is extremely flexible and can also process materials to which wire-based coating processes do not have access. Particular advantages become obvious when coatings are necessary made from high chromium containing steels,metal matrix composites (MMCs) or pure ceramics.The compositions of the coatings can be tailored to the specific challenges in an engine, e.g. preventing excessive abrasive wear, scuffing issues or corrosion attack caused by bad quality fuels and/or high exhaust gas recirculation rates (EGR). Cylinder liner surfaces from trucks, diesel locomotives and marine propulsion,gas engines for power generation and gas compression have been coated with such materials over the past four to five years in small and large series production. These engines have been tested successfully.Most of the tested engines achieved significant reductions of lubrication oil consumption (LOC), one of them in excess of 75%, reduced fuel consumption, very low wear rates and corrosion resistance on the liner surfaces, when compared to the currently uncoated cylinder surface (baseline). The paper will introduce the APS coating technology for ID cylinder surfaces and as an example will highlight the coating of cylinder surfaces in a 4,000 hp EMD 16-710G3 locomotive 2-stroke diesel engine. Details of the application of a corrosion resistant MMC coating will be shown, together with results obtained with the Da Vinci DALOC measurement technique in an engine test where the lubricant oil consumption was accurately quantified at 4 steady-state operating conditions typical of North American freight locomotive and which clearly showed the significant contribution of the liner ID coating to reduction of lubricant oil consumption (LOC). In addition the paper will give an example of an industrialized, fully automated SUMEBore coating equipment installed at a European truck OEM, for the APS cylinder surface coating of up to 250000 cylinder liners for a truck engine.

【会议名称】

第27届CIMAC会议

【会议地点】

上海

【下载次数】

1

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