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.

福特加拿大和不列颠哥伦比亚大学欧肯娜根大学之间的这种伙伴关系旨在提高下一代汽车发动机的效率和性能。到2025年，该项目的成功完成可以帮助汽车行业实现严格的政府强制执行的燃油经济性目标54.5 mpg。为了实现这一目标，有必要调查重量轻巧的发动机和/或开发新的制造过程的新方法，以消除已知的问题，以降低发动机的热效率或限制发动机的热效率。在铝（AL）发动机块的制造过程中，材料特性的差异会导致许多有害问题，包括但不限于产生残余压力（即，在没有外部负载的情况下将其锁定在材料中）。这些问题削弱了材料，主要是由于在发动机块中使用的铁（Fe）衬里的存在引起的，以保护较软的基本材料免受磨损的影响。为了减轻FE班轮的缺点，制造商已经开始使用耐磨涂料。福特是实施称为等离子体转移电弧（PTWA）的涂层过程的早期开拓者之一。尽管它在2011年的野马GT中证明了它的稳健性，但我们的试点研究证实，在PTWA过程中发生的快速传热仍然导致产生高达100mPa的拉伸残留应力。此外，相对较厚的涂层的导热率较差会导致较大的峰缸温度，从而导致发动机效率降低。因此，开发了一种较新的方法，即电解射流血浆氧化（EJPO），该方法具有通过最大程度地减少其应用过程中产生的热梯度来降低残余应力的积累的潜力。因此，这项研究旨在表征涂料过程对福特新V8发动机块中残留应力的影响。此外，将检查新EJPO涂层的表面纳米孔隙率，石油保留和耐磨性，以确定将EJPO涂层用于新发动机的质量生产的可行性。