“The high EGR rate and use of high-sulfur diesel fuel will create severe challenges for wear on the surface of cast iron boreholes.†Gian Maria Olivetti, Chief Technology Officer, Federal-Mogul Powertrain, stated, “Using Advanced Thermal Spray Cylinder Solutions For example, Federal-Mogul's Sprayfit thin-wall liners can effectively combine heat dissipation with the benefits of a wide range of wear-resistant surfaces, but we still need to take a reliable approach to evaluate the performance of alternative materials, and we now have a proven track record. Mature process to achieve this goal."
Federal-Mogul Powertrain delivers more durable products through innovative processes for the most challenging applications
Before that, there was no universally recognized method in the industry to compare the corrosivity of different materials during engine operation. Therefore, the innovative technology adopted by the Federal-Mogul Powertrain has brought new breakthroughs to the industry. Given the complex relationship between mechanical wear and corrosion, each factor must be evaluated independently to determine the most wear-resistant material.
Mechanical wear removes corrosion products, exposing unprotected surfaces and accelerating corrosion. Due to the poor wear resistance caused by the corroded surface, the wear phenomenon in the continuous cycle is further deteriorated.
Fiamond Powertrain Thin-wall Thermal Spray Sprayfit Cylinder Micro-section
The Federal-Mogul powertrain can accurately regenerate the corrosive solutions formed in the interior of the engine by combustion, including sulfuric acid, nitric acid, and acetic acid, and uses these substances for a series of tests. Specific tests include: immersion testing with a boiling solution of the appropriate composition, and metallographic examination, electrochemical studies at temperatures close to the flash point of the solution. By controlling the test solution, Federal-Mogul can regenerate the characteristics of a typical sulfur condensate or EGR condensate.
Test results show that the exposure to sulfur condensate has the highest corrosion rate. At the same time, Federal-Mogul used the conventionally manufactured cast iron number as a reference to compare the effects of sulfur condensate on various materials. The study found that as the chromium content increases, the corrosion resistance increases accordingly, but as the oxides of the material (iron oxide, chromium oxide) increase, the corrosion resistance shows a downward trend.
“Through this test we were able to determine that the necessary corrosion and wear resistant materials and surface coatings were available to meet the most demanding cylinder liner applications.†Dr. Volker Scherer, Business Director, Federal-Mogul Powertrain Cylinder, said. "Through close cooperation with our customers, we have designed material properties from the very beginning so that products can meet the different challenges that different applications bring."
The Federal-Mogul Powertrain will use the research results to supply finished and semi-finished liners, which will point the way for future diesel engine manufacturers' material selection.
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