Few Surface Treatment Techniques for some of the Automotive

components

Surface enhancement engineering solutions are becoming more and more the goal
of the automotive industry in reduction of wear, friction and corrosion for powertrain parts
and engine interiors.

Surface Treatment techniques for few powertrain components:

The conventional Al cast alloys with 7% to 9% Si do not produce the necessary

tribological properties for the piston group. The most frequently used tribological solution for
engine blocks in aluminium cast alloys is the insert of cast iron sleeves. However, the insertion
of cast iron sleeves presents several disadvantages. The pitch distance is still relatively high in
comparison with the bore diameter. The heat flow from cylinder bore to the cooling system
is not regular. The oxides between the cast iron sleeves and the Al cast material have a
negative influence, because they are not homogeneously distributed and some distortion of
the bores results. The distortion of the bores increases the tendency for blow-by and has a
negative influence on the power generated. The internal plasma spray coatings can be used
in the production of a variety of gasoline and diesel engines.

Piston rings have to seal the combustion gas and to control the lubrication oil. The
surface treatment can be used to reduce wear and to prevent seizure. A variety of piston rings
exists for different applications. Besides the different substrate materials, also different
surface treatments can be used. Depending on the application and the manufacturing costs,
spraying, galvanizing, nitriding, PVD coatings and the combination nitriding plus PVD coating
can be used. The most expensive method is the PVD-method. About 10–50 um thick Cr-based
coatings are deposited mostly by vacuum arc evaporation.

Plasma nitriding of metallic components of different materials is one of the well-

established treatments (for crankshafts, springs, synchronizers, etc.) resulting in improved
performance due to an increase of the hardness, fatigue strength and creation of residual
compressive stresses. However, PVD coatings are more wear resistant (adhesive wear, micro
abrasion, oxidation, etc.). The combination of nitriding and PVD provides a product superior
to both. The nitriding before the deposition of the hard coating increases the load bearing
capacity of the coating-substrate-system. This combination treatment is industrially used for
high loaded piston rings. However, more applications might be realized in the powertrain and
engine.