Analysis and Optimization of Electrolytic Jet Plasma Oxidation (EJPO) Coating for Manufacturing of High-Efficiency Automotive Engines

用于制造高效汽车发动机的电解喷射等离子体氧化 (EJPO) 涂层的分析和优化

• 批准号: 566184-2021
• 负责人: Sediako, DimitryDG
• 金额: $ 1.47万
• 依托单位: University of British Columbia
• 依托单位国家: 加拿大
• 项目类别: Alliance Grants
• 财政年份: 2022
• 资助国家: 加拿大
• 起止时间: 2022-01-01 至 2023-12-31
• 项目状态: 已结题
• 来源: https://www.nserc-crsng.gc.ca/ase-oro/Details-Detailles_eng.asp?id=761739
• 关键词: Analysis; Optimization; Electrolytic; Jet; Plasma

This partnership, between Ford Canada and the University of British Columbia Okanagan, aims to improve the efficiency and performance of the next generation of automotive engines. The successful completion of this project could help the automotive industry meet the strict governmentally enforced fuel economy target of 54.5 MPG by 2025. To accomplish this goal, it is necessary to investigate new methods of lightweighting the engine and/or developing new manufacturing processes to eliminate known issues that lower or restrict the thermal efficiency of the engine. During the manufacturing process of aluminum (Al) engine blocks, differences in material properties cause a number of harmful issues to develop, including but not limited to the generation of residual stress (i.e. stress that is locked in the material without an external load). These issues weaken the material and are primarily caused by the presence of the iron (Fe) liners that are used in engine blocks to protect the softer Al base material from wear. To alleviate the drawbacks of the Fe liners, manufacturers have begun using wear-resistant coatings instead. Ford was one of the early pioneers to implement a coating process known as plasma transferred wire arc (PTWA). Although it proved its robustness in the 2011 Mustang GT, our pilot study confirmed that the rapid heat transfer that occurs during the PTWA process still leads to the generation of the tensile residual stress of up to 100MPa. Moreover, the poor thermal conductivity of the relatively thick coating results in larger peak cylinder temperatures which lead to a decrease in engine efficiency. Thus, a newer method, electrolytic jet plasma oxidation (EJPO), was developed which has the potential of lowering the accumulation of residual stress by minimizing the thermal gradients produced during its application. Thus, this study aims to characterize the effects that the coating processes have on the residual stress in Ford's new V8 engine block. Moreover, the surface nano-porosity, oil retention, and wear resistance of the new EJPO coating will be examined to determine the feasibility of using EJPO coating for mass production of the new engine.

福特加拿大公司和不列颠哥伦比亚大学奥肯那根分校之间的合作旨在提高下一代汽车发动机的效率和性能。该项目的成功完成可以帮助汽车行业实现政府强制执行的到 2025 年 54.5 MPG 的严格燃油经济性目标。为了实现这一目标，有必要研究轻量化发动机的新方法和/或开发新的制造工艺来消除降低或限制发动机热效率的已知问题。在铝 (Al) 发动机缸体的制造过程中，材料特性的差异会导致出现许多有害问题，包括但不限于残余应力的产生（即在没有外部负载的情况下锁定在材料中的应力）。这些问题会削弱材料的强度，主要是由于发动机缸体中使用的铁 (Fe) 衬里的存在造成的，以保护较软的铝基材料免受磨损。为了减轻铁衬里的缺点，制造商已开始使用耐磨涂层。福特是实施等离子转移丝电弧 (PTWA) 涂层工艺的早期先驱之一。尽管在 2011 年野马 GT 中证明了其稳健性，但我们的试点研究证实，PTWA 过程中发生的快速传热仍然会导致产生高达 100MPa 的残余拉应力。此外，相对较厚的涂层的导热性较差，导致气缸峰值温度较高，从而导致发动机效率下降。因此，开发了一种更新的方法，电解喷射等离子体氧化（EJPO），它有可能通过最大限度地减少应用过程中产生的热梯度来降低残余应力的积累。因此，本研究旨在表征涂层工艺对福特新型 V8 发动机缸体残余应力的影响。此外，还将对新型EJPO涂层的表面纳米孔隙率、保油性和耐磨性进行检验，以确定使用EJPO涂层用于新型发动机批量生产的可行性。