Nano Honing
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THE FUTURE in engine design
Thermal spray coats in cylinder bores of internal combustion engines are high-performance materials of the future. Energy efficient engines with low friction, reduced length and lower weight as well as lower production costs can be achieved due to the new process chain for the manufacture of cylinder bores.
To this end, the process chain includes the following processes:
- Mechanical roughing
- PTWA coating
- Overspray jets
- Honing
Principles of Nano honing
To achieve a high degree of adhesion when coating, mechanical roughening (pre-treatment) as a variant of precision boring is required. Mechanical roughening is realized through cutting processes and combined processes consisting of cutting and forming. The following PTWA coating (Plasma Transferred Wire Arc) works with a plasma light arc in which the supply wire is melted and then sprayed onto the cylinder bore. This results in a hard, wear-resistant, ductile and easy to hone cylinder liner coating.
After the thermal coating follows the overspraying jets in which overspray particles are removed from the casting surfaces below the coated cylinder bore by means of water jets. Expensive masking is no longer required and the process chain is thereby ready for production.
The subsequent honing, a multiple-step precision machining process, creates the low-friction surface with a high degree of dimensional and form accuracy in the cylinder liner which is needed for the engine.
Components of Nano honing
To implement manufacturing of nano honing, the single processes as roughening, coating and honing have to be combined. The roughening with Gehring Diato tools occurs with feeded processing spindles. During thermal coating the actual cylinder lining is sprayed-on with little iron particles. Thereby RSW, PTWA, LDS or APS processes are used.
The nano honing closes with a specific aligned honing process on Gehring honing machines. If required one can integrate in the overall process washing operations before coating as well as overspray cleaning after coating. During coating possible occured particle disposals under the boring can be removed with overspray cleaning. For this cleaning, a water-soluble coolant under high pressure is brought in the appropriate range through a steel tool.
During coating possible occured particle disposals under the boring can be removed with overspray cleaning. At this, a water-soluble coolant under high pressure is brought in the appropriate range through a steel tool.
THE PROCESS CHAIN OF NANOHONING
The Sturm Advanced Cylinder Coating System (ACCS) is the efficient and modular solution for producing coated cylinder surfaces in modern crankcases or liners. The thermal spraying process uses a single wire as starting material and allows for a variety of coating properties.
In order to be able to offer the entire process chain „roughening - coating - honing“ Gehring has integrated the ACCS-TWS (Thermal Wire Sprayer) into its technology center. The loading and unloading area of the ACCS-TWS is equipped with the Cylinder Inspector. This enables direct quality control before and after coating as well as an automatic thickness layer adjustment possibility.
Trust in the technology leader with many years’ experience and global presence! Innovative technology combined with an economical mindset sets us apart.
The objective of Nano honing
An overall result of this process chain is a marked reduction in friction, which considerably contributes to reducing fuel and oil consumption.
Therefore, a considerable contribution to modern internal combustion engines with a high degree of energy efficiency, low emission values and longevity is also made.
Your benefits
The nano honing process chain leads through a combination of roughening, coating and honing technologies to particularly friction reduced and tribological optimated cylinder lining.
Thus, a wear-resistant coating with system-immanent porosities as lubricate volume and at the same time very fine honed surface is realized.
Our Products:
powertrainhone
Our model series powertrainhone is especially optimized for the machining od engine blocks and cylinder liners. Whether machining of cylinder or crankshaft bore, whether modular variant or transfer line, we offer the right solution.