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Quality Designed Twin Wire Arc Spraying of Aluminum Bores

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Abstract

After 125 years of development in combustion engines, the attractiveness of these powerplants still gains a great deal of attention. The efficiency of engines has been increased continuously through numerous innovations during the last years. Especially in the field of motor engineering, consequent friction optimization leads to cost-effective fuel consumption advantages and a CO2 reduction. This is the motivation and adjusting lever of NANOSLIDE® from Mercedes-Benz. The twin wire arc-spraying process of the aluminum bore creates a thin, iron-carbon-alloyed coating which is surface-finished through honing. Due to the continuous development in engines, the coating strategies must be adapted in parallel to achieve a quality-conformed coating result. The most important factors to this end are the controlled indemnification of a minimal coating thickness and a homogeneous coating deposition of the complete bore. A specific system enables the measuring and adjusting of the part and the central plunging of the coating torch into the bore to achieve a homogeneous coating thickness. Before and after measurement of the bore diameter enables conclusions about the coating thickness. A software tool specifically developed for coating deposition can transfer this information to a model that predicts the coating deposition as a function of the coating strategy.

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Abbreviations

LDS:

Lichtbogendrahtspritzen (German word for “twin wire arc spraying”)

TWAS:

Twin wire arc spraying

NEDC:

New European driving cycle

OFAT:

One factor at time

DoE:

Design of experiments

CAE:

Computer-aided engineering

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Authors and Affiliations

  1. RD/RMP, Research & Development, Daimler AG, 89081, Ulm, Germany

    Johannes König, Michael Lahres & Oliver Methner

Authors
  1. Johannes König
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  2. Michael Lahres
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  3. Oliver Methner
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Corresponding author

Correspondence to Johannes König.

Additional information

This article is an invited paper selected from presentations at the 2014 International Thermal Spray Conference, held May 21-23, 2014, in Barcelona, Spain, and has been expanded from the original presentation.

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König, J., Lahres, M. & Methner, O. Quality Designed Twin Wire Arc Spraying of Aluminum Bores. J Therm Spray Tech 24, 63–74 (2015). https://doi.org/10.1007/s11666-014-0170-6

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  • DOI: https://doi.org/10.1007/s11666-014-0170-6

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