No powertrain without Miba Technology

Company
Speaker
Miba Coating Group
Eitzinger Günter
Chief Engineer
No powertrain without Miba Technology
TT-KC, TT-HS
CONFIDENTIAL
Coatings Examples Super low-friction DLC – Bearingless
Conrod – Substitution of bushings –Silent Gears - Spacecoat
1) MIBA Coating Group, 2) University of Leoben, 3) WZL Aachen
Teer Coatings Ltd, Miba Coating Group
www.miba.com
TT-KC, TT-HS
CONFIDENTIAL
Innovation in Motion
Agenda





Motivation
High Temperature DLC
Replacement of bearings and bushings – Conrod
Adaptive Coatings on gears Spacecoat Coating
Summary
Innovation in Motion
Motivation
Source: A.Merkle, M.Werner, Technical University of Munich, Institute of Combustion engines ©2008-2009
Innovation in Motion
Diamond like carbon (DLC) Classification
Innovation in Motion
High Temperature DLC Deposition
Deposition parameters:
•Unbalanced magnetron sputtering
•Ar-plasma
•Temperature: < 200°C
•Rotation: 8-10 rpm
•Bias: - 60 V / pulsed 50 kHz
•Deposition Pressure: 0.3-0.4 Pa
•Substrates: M42 tool steel, Si (100)
Coating architecture
Graphit-iC layer
Ramp: 100 at% Cr → 100 at% C
Cr-Interlayer
Substrate
 2 µm
 0.5 µm
 0.1 µm
Innovation in Motion
Depth [µm]
Friction coefficient µ
Graphit-iC™HT (Hardness ~1900HV)
3D View
Sliding distance [m]
Ball-on-Disc Test:
 Applied Load: 10N @ 325°C
 Friction coefficient ~ 0,05
 Very low specific wear
1.2 mm
0.9mm
Innovation in Motion
100Cr6 Ring-on-Disc, 2MPa, 120°C
Oil: Shell Helix Ultra (5W30)
coated disc
uncoated disc
sliding speed
Coated / Uncoated = -30%
Innovation in Motion
Possible application










Piston Pins
Piston Skirt
Piston Ring
Liner
Tappets
Valves
Cam
Conrod
Camshafts
Turbocharger components
Innovation in Motion
Bearingless Conrod – Direct coating
1.
2.
3.
4.
5.
6.
7.
8.
9.
Increased load ability
Smaller bearings
Less hydrodynamic friction
Smaller tolerances
Reduced Weight
Increased stiffness
Smaller engine
Less oil consumption
Smaller oil pump
Example picture
Innovation in Motion
Bearingless Conrod – Direct coating
1. Layer
2. Layer
AlSn20Cu PVD
Synthec®Pro
High Loadability
Running in
Innovation in Motion
Examples of Sputter Machines
Capacity and Capability:
Millions of Parts All Metals and alloys, Nitrides…
Innovation in Motion
Possible App. - Post Magnetron Technology
Also possible to coat liners with CrN and DLC
Friction reduction
Innovation in Motion
Hydro-dynamic Bearing Performance
Kleinster Schmierspalt [µm]
min oilfilm thickness [µm]
0.8
0.9
1
Bauarten / Bearing Types
Prototype
Standard
Development
Sputter NEW
Application Area Sputter .
Sputter Bearing
Application Area Tri-Metal .
2
Synthetic OL
PnSnCu PRO
Rillenlager
SnSb PRO
3
Tri-Metal Bearing
BIAL AlSn25
AlSn20
BIAL AlSn20
4
AlSn40
5
1000 1500
Outstanding
Hydrodynamic
Performance
Application Area Bi-Metal .
2000
2500
3000
3500 4000
4500 5000
Schmierfilmspitzendruck [bar]
max Oilfilm Pressure [bar]
5500
Innovation in Motion
Sliding lacquers: Synthec™Pro
Engine : EA 888 Audi 4 Cylinder Gasoline (World engine)
Integrated Mass Balancer System
Reason: Engine Start Stop –coating reduce friction and increase emergency
behaviour of the system
Rotational speed :
max. 14000 rpm
Max. Torque:
max. 60 Nm
One Radial- and two integrated axial bearings on a net shape sintered part
Innovation in Motion
Detail Synthec®Pro on Sintermaterial
Innovation in Motion
Test results COF versus Load of Synthec Pro
®
100Cr6 ring against SynthecPro on 1.2379 hardened
under Shell Helix Ultra 5W30@55°C
cycles [1]
0
200.000
400.000
600.000
800.000 1.000.000 1.200.000 1.400.000 1.600.000
0,2
6
0,18
friction coefficient
0,14
4
0,12
0,1
3
0,08
2
0,06
0,04
1
0,02
0
0
10000
20000
30000
40000
50000
sliding distance [m]
60000
70000
80000
0
90000
specific load
5
0,16
friction coefficient [-]
specific load [MPa]
Innovation in Motion
Application examples of Synthec Pro
sliding bearings
split gears
piston skirt
sprockets
bearing block
intermediate gears
Innovation in Motion
Synthec Pro Properties
Performance Attributes








Very wide temperature range in applications (-50 up to 300° C)
Superior wear resistance
Corrosion resistance
Adaptive behaviour
Avoidance of frictional corrosion
Environmental friendly
Potential for weight reduction
Potential for cost reduction
Innovation in Motion
Silent Gears
Cr/Ag or CuSnC
coating system:
(Immiscible; Hardness adjustable
between 200 and 1000HV)
4 layers visible
Coating thickness: 16µm
Interlayer thickness: 1,5-2 µm
Innovation in Motion
Results
NVH Test Rig
 2 servo engines
 adjustable axis
distance and
backlash
 0 – 6000 rpm
 0 – 20 Nm oscillating
torque
 up to 10 Hz
Innovation in Motion
Uncoated vs. Coated gear
10dB Differenz
Innovation in Motion
Summary
• Reducing CO2 emission is one of the top priorities for the
automotive industry and us
• Coatings technology is a key for reduction of friction and
enabler for new technical solutions
Thank you for your attention.
Innovation in Motion
Contact
Miba Coating Group
Günter Eitzinger
Advanced Engineering
Dr. Mitterbauer-Str. 3
A-4655 Vorchdorf, Austria
T +43/7614/6541-8200
F+43/7614/6541-8400
M +43/664/8560418
www.miba.com
[email protected]