Common rail fuel injection needs multiple injections per cycle to improve combustion. Car manufacturers require more than several million injections without significant wear of the engine components. Furthermore heavy duty manufacturers require engines to last at least one million miles without any significant wear. The European emission norm becomes stricter every few years and is applicable on a worldwide scale.
One way to comply with these stricter regulations and improve the performance of the engine, is the use of PVD coating and PACVD coating on components. By developing the right plasma coatings for specific components in accordance with the lubrication, better wear resistance and friction reduction can be achieved .
A PVD coating, such as chrome nitride coating (CrN coating) on piston rings can extend the lifetime of the engine considerably.
Friction reduction is another reason to apply PVD coating or PACVD coatings on engine components. In a normal car 10-15% of the energy use is wasted on friction losses. Due to a tribological Diamond Like Carbon coating (DLC coating) on e.g. valve train components, a friction reduction of 40% can be achieved, resulting in 1-2% less CO2 emission. When the DLC coating is applied with PACVD technology it is a very cost-effective method, because no expensive target materials are needed.
The main advantages of engine coatings are:
- Better wear resisistance and friction reduction
- Improved fuel economy
- Lower CO2 emissions
Tribological PVD coatings and PACVD coatings are often applied on the following engine components:
- Turbo diesel injection parts
- Valve train components
- Drive train components
- Roller / sliding bearings
- Piston pins
- Piston rings
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