Friction and wear reduction in heavy-duty diesel powertrains Project Wonaco2 - Tribodays, Örnsköldsvik

2 Project Wonaco2 Engine tribology 101 ANS Triboconditioning Project focus and results Summary

3 Research project involving ANS, LTU, UU, HH, Volvo Powertrain and Scania Funding from ProViking (SSF) Objective was to assess if Triboconditioning could be used to reduce friction in diesel engines Started in mid 2010 and soon to be concluded

4 Project Wonaco2 Engine tribology 101 ANS Triboconditioning Project focus and results Summary

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6 Friction losses 15% Friction losses 15% Heat losses (exhaust, cooling, etc.) 60% Heat losses (exhaust, cooling, etc.) 60% Useful kinetic energy 25% Useful kinetic energy 25% * Auxiliary systems, injection pump, etc. 15% of all energy supplied to an engine is lost due to friction

7 Project Wonaco2 Engine tribology 101 ANS Triboconditioning Project focus and results Summary

8 Steel surface Process Fluid TEM-image of the coating Tool

9 CORE METHOD Turning USAGE Steel surface Tool F v Honing Hydraulic rods Cylinders Camshafts Turbine shafts CrankshaftsRockdrills Bearings Piston pins APPLICATIONS

10 Controlled Running-in Peaks removed (R pk reduced) Nano-composite TRIBO-layer to reduce friction and wear Original surface Triboconditioned surface Triboconditioning improves surface finish and deposits a low-friction tribolayer in one process step

nm Amorphous deposited film

12 Lowered boundary friction due to easily sheared nano-composite coating Surface layer prevents asperity-asperity contacts and the coating improves oil affinity, hence the shift to the left of the curve

13 Project Wonaco2 Engine tribology 101 ANS Triboconditioning Project focus and results Summary

14 How is the topography changed? Before and after? How fine surfaces can be manufactured? Can manufacturing steps be replaced? How do the process parameters effect the surface (chemistry and topography)? How can the chemistry in the tribolayer be controlled? What does the film look like? Contents? Hardness? Morphology? How good are the surfaces in different tribo systems? Triboconditioning Pressure Time Chemistry fluid Chemistry tool Temperature

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16 Roller tapper shaft, Triboconditioned bearing positions Schematic picture of Scania valve system

17 Friction reading; ANS triboconditioning vs Reference Wear marks on counter surface after friction test above From left to right: ANS triboconditioning, Reference 1, Reference 2 Results – Friction & Wear

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19 Results – Friction & Wear Wear marks on counter surface after friction test From right to left: Reference, ANS coating A2, ANS coating A3

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24 Coated cylinder liner

25 Load: 100 N Ring: CrN PVD ring Oil: SAE 30 Oil temperature: 20°C

26 COATED Stroke: 24mm Load: 8N Velocities: 1Hz Time: 10min Nominal contact pressure: 1.42 MPa 10mm wide liner samples Liner samples half- coated,half-uncoated New twin land oil control ring

27 Project Wonaco2 Engine tribology 101 ANS Triboconditioning Project focus and results Summary

28 Triboconditioning can be used to reduce frictional losses in heavy duty diesel engines Good results in 10+ projects so far (Volvo, Scania, Mahle, Federal Mogul, Gnutti, Ford, Atlas Copco Secoroc, Tetra Pak, Hägglunds Drives, Bosch, BodyCote,...) Wonaco2-projektet gave us a great opportunity to do advanced research in the area of Triboconditioning We will now continue our work to get the triboconditioning method in production!

29 TAE STLE TLT EcoTrib

Mattias Karls,