Laser interference functionalized light metal hybrid ceramic
Federal Ministry of Education and Research (BMBF)
Program: SME-innovative: Resource efficiency and climate protection
Project duration: 01.04.2019–31.03.2021
Total allocation: 786.000 €
ELB - Eloxalwerk Ludwigsburg Helmut Zerrer GmbH
Fraunhofer Institute for Material and Beam Technology (IWS)
The piston group, consisting of pistons, piston rings and cylinder liners, accounts for the largest share of frictional losses within a gasoline engine (48 %). Friction and wear optimization within the piston group - particularly at the cylinder surfaces - can reduce friction loss by up to 60 %. This results in a CO2 reduction of up to 4 %. In absolute figures, this means a saving of 3.25 million liters of fuel for newly registered cars in Germany and thus a reduction of 8073 tons of CO2.
Goals and procedure
In a first step, the project focuses on the development of an innovative wear protection by means of a composite hybrid coating consisting of a ceramic surface and a polymer wear layer for moving lightweight applications in bearing and engine technology, in particular for cylinder surfaces made of Al-Si alloys. As a result, friction and thus fuel consumption can be significantly reduced and wear resistance increased. In a second step, by means of the Direct Laser Interference Patterning (DLIP) approach, microcavities are created, so that emergency running properties in conjunction with the polymer inclusions in the hybrid layer are guaranteed.
Innovations and perspectives
A targeted surface-modified coating of cylinder running surfaces in Al-Si engine housings will adapt them to the increased requirement profile of today's engine technologies. At the same time, the technologies, which are necessary to improve this functionality, should be designed to be energy-efficient and resource-saving. In particular, high-energy processes are to be avoided and the material needed for cylinder bore surface machining is to be minimized.