Coating engine components with hard carbon reduces friction to almost zero – a development that could save billions of liters of fuel worldwide every year. Now researchers have developed a new laser method to apply the coating on the production line
Scientists already know how to coat components with diamond-like carbon to minimize friction. But now Fraunhofer researchers have developed a laser arc method with which layers of carbon almost as hard as diamond can be applied on an industrial scale at high coating rates and with high thicknesses.
By applying carbon coatings to engine components such as piston rings and pins, fuel consumption can be reduced. “Systematic application of our new method could save more than 100 billion liters of fuel each year over the next ten years,” says Prof. Andreas Leson from the Fraunhofer Institute for Material and Beam Technology IWS in Dresden, referencing a study that was published in the journal Tribology International in 2012.
Carbon-based coatings are already used in volume production. But now the team of IWS researchers led by Prof. Leson, Dr. Hans-Joachim Scheibe and Dr. Volker Weihnacht has succeeded in producing hydrogen-free ta-C coatings on an industrial scale at a consistent level of quality. These tetrahedral amorphous carbon coatings are significantly harder and thus more resistant to wear than conventional diamond-like coatings. “Unfortunately, you can’t just scrape off diamond dust and press it onto the component. So we had to look for a different method,” says Dr. Scheibe, who has spent over 30 years investigating carbon’s friction-reducing properties…
SOURCE: REX RESEARCH