1. Technical University of Koszalin Department of Mechanical Engineering

2. Co-ordinator: dr Jerzy Ratajski Technical University of Koszalin Koszalin, Poland mail to: jratajsk@tu.koszalin.pljratajsk@tu.koszalin.pl Fax: +48(0-94)-34-26-753 Development of intelligent tools for processes of surface treatment in automotive, railway, ship building and aircraft industry.

3.  hardening by cold work (burnishing),  thermochemical heat reatment: carburizing, carbonitriding, nitriding,  glow discharge nitriding,  techniques of PA PVD and PA CVD. Processes of surface treatments

4. Samples of application of the surface treatment to land transport

5. Automotive industry Carburising and carbonitriding: Cams, camshafts, starter shafts, pins, articulated joints, gears, eccentric, chain wheels, king-pins, ratchet mechanism, spline shafts, bearings, bearing bushs, valve spindles. Nitriding: Crancshafts of Diesel engine, serrated shafts, elements of car steering system, elements of injectors to Diesel engine, valve arms, timing gears, ring gears of back axle (truck), adjusting plates, gears, cylinders liners, spindles, worms, cams, shafts, pistons pin, starter couplings, transmission coupling, gaskets, bearings, elements of speed indicators, axles, pistons, elements of window-opening mechanism, differential housing, rocker arms, clutch hubs, exhaust valves, batch of hydraulic cylinders, elements of windscreen wipers. Glow discharge nitriding: werms, feed cylinders, guide screws of transmission, transmission gears, crancshafts, crancshafts of Wankel rotary piston engines, crancshafts of Leyland rotary piston engines, valves, shift forks, clamping rings, clamping pads, cylinders liner of Diesel engine. PA PVD PA CVD techniques: engines and transmision – cams surface, tappet foot, gears transmission, ball bearings, roller bearings. Surface cold working (burnishing): crancshafts, lever of steering rods, steerings knuckle arms, springs, elements of air cushions, gears transmision, worm gears, axles, shafts.

6. Railway industry Carburising and carbonitriding: wagon’s wheels, systems of gear transmission. Nitriding: hydraulic buffers, brake pins, guide valves, disk valves, piston rings, timing gears, piston pins. Surface cold working (burnishing): craneshafts ??surface.

7. Air transport Carburising and carbonitriding: assembly elements of aircraft engines, connecting links. Nitriding: parts of engines and pumps, such as: cylinders liner, crancshafts, shafts, timing gear cams, mandrels, pistons rings, gudgeon pins. Surface cold working (burnishing): engines parts e.g.: gears, transmission gears, shafts, exhaust stacks, landing gears, propellers. PA PVD PA CVD techniques: above 75% of aircraft engine parts is covered by PA PVD and PA CVD techniques.

8. Sea transport Carburising and carbonitriding: shafts of large ships engines and outboard motors, connectors. Surface cold working (burnishing): large gears transmission, crancshafts, power screws.

9.  proper selection of treatment processes should lead to synergic effects in terms of final properties of the product,  nowadays parameters of these processes are not optimized,  duplex or multiplex processes implemented by industry are very often a result of successive trial and error tests NEEDS: Development of intelligent tools – data bases and expert systems supporting design and control of surface treatment processes. Modern process of surface treatment is a complex combination of individual/complementary techniques

10. design of unconventional combinations of conventional treatment processes an optimal selection of algorithms describing changes of single process parameters Burnishing Thermochemical treatment or glow discharge nitriding PA PVD PA CVD These tools should enable:

11. It in frames of project was planned:  creation of experimental model systems of processes of surface treatment  elaboration of intelligent tools – data base and expert systems for processes of surface treatment  searching for optimal as regards multi-functionality, multi-component coatings obtained by means of PVD and CVD methods, among other nano-structured diamond, diamond like and carbide derived carbon films  development of intelligent control systems

12. Innovation Activities R&D Experimental Verification WP0 Management & Dissemination Leader WP: TUK WP1 System Creation of Experimental Data Base WP5 Experimental Verification Expert Systems and Models of Control Systems WP4 Control Systems WP3 Expert Systems WP2 Modelling of Properties and Processing

13. Research directions Thermochemical heat treatment of steel: nitriding, carburizing, carbonitriding  studies of nitriding process kinetics,  development of mathematical models,  development of sensors for in-situ process monitoring and control,  design of advanced control systems.