Materials & Advanced Manufacturing (M&AM) Adaptive Graphite - - PowerPoint PPT Presentation

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Materials & Advanced Manufacturing (M&AM) Adaptive Graphite - - PowerPoint PPT Presentation

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Materials & Advanced Manufacturing (M&AM) Adaptive Graphite Coatings Improve Fit and Function of Pistons, Turbos and Other Precision Devices Andrew Suman President, Line 2 Line, Inc. 4866 White Lake Rd. Clarkston, MI 8/10/2018

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SLIDE 1

Materials & Advanced Manufacturing (M&AM)

8/10/2018

Adaptive Graphite Coatings Improve Fit and Function of Pistons, Turbos and Other Precision Devices

Andrew Suman President, Line 2 Line, Inc. 4866 White Lake Rd. Clarkston, MI

UNCLASSIFIED: Distribution Statement A. Approved for public release; distribution is unlimited

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SLIDE 2

Materials & Advanced Manufacturing (M&AM)

Improves Fit and Function

2

  • Graphite Coatings polish themselves to a perfect fit, minimizing

clearances, improving oil films & enhancing efficiency

  • Graphite coatings are engine friendly and do not react with motor oils and

transmission fluids

  • Protects components from sand
  • Reduces (Re)Manufacturing Costs – Cheap and easy to apply
  • Improves Engine Efficiency 7%

(Rubel -Cummins 14.7L diesel turbo)

  • Extends Part Life 300%

(Plutz -Rotax 500 top end life)

  • Decreases Noise 50%

(L2L – Shindiawa piston)

  • Increases Idle Oil Pressure 100%

(Riley – gerotor pump)

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SLIDE 3

Materials & Advanced Manufacturing (M&AM)

8/10/2018 UNCLASSIFIED: Distribution Statement A. Approved for public release; distribution is unlimited

Adaptive Abradable Powder Coatings (AAPC’s) - Applications

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SLIDE 4

Materials & Advanced Manufacturing (M&AM)

8/10/2018 UNCLASSIFIED: Distribution Statement A. Approved for public release; distribution is unlimited

AAPC Attributes

  • Unique patented process
  • Blend of plastics and solid lubricants that makes graphite stick

to automotive parts

  • Thin or thick – 20 micron to 250 + micron
  • Coating hardness/texture/thickness tuned for applications
  • Self-fitting – via dry abrasion or lubricated Stribeck Fitting
  • Seats in quickly - lasts life of device
  • Improves performance, TBO, and life
  • Enhances manufacturability
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SLIDE 5

Materials & Advanced Manufacturing (M&AM)

8/10/2018

AAPC Utilization Since 2000

  • Over 16M automotive powertrain components
  • Commercial- ~45,000 pistons of all types, screw compressors,

turbo housings, roots blowers, oil pumps, vacuum pumps, lifters, cams, bearings, vintage component restorations

  • Military – drone pistons, advanced engine development, air

pumps

UNCLASSIFIED: Distribution Statement A. Approved for public release; distribution is unlimited

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SLIDE 6

Materials & Advanced Manufacturing (M&AM)

8/10/2018 UNCLASSIFIED: Distribution Statement A. Approved for public release; distribution is unlimited

AAPC’s – How They Work

  • Add coating to standard size or worn metal components
  • Coat thick enough to build it tight (light interference-OK)
  • Break-in during initial operation perfect fit and uniform loading

between mating parts

  • Ideal geometry lasts

– Minimize clearances 3D for efficiency – Reduces vibration, shock loads, oil film failures – Extends Time Before Overhaul (TBO) and Life

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SLIDE 7

Materials & Advanced Manufacturing (M&AM)

8/10/2018 UNCLASSIFIED: Distribution Statement A. Approved for public release; distribution is unlimited

AAPC Has Texture & Thickness

  • Texture aids break-in
  • Finds ideal component shape, topography supports oil film

Prior to Break-In After Break-In

Magnifications ~150X

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SLIDE 8

Materials & Advanced Manufacturing (M&AM)

8/10/2018 UNCLASSIFIED: Distribution Statement A. Approved for public release; distribution is unlimited

AAPC Topographic Advantage

After Brk-In

The image part with relationship ID rId2 was not found in the file. The image part with relationship ID rId2 was not found in the file.

AAPC Thin Liquid SFL

Thickness 47.8µm New Ra 2.2µm Rz 13.3µm mr1 8.3% mr2 91.5% Thickness 41.6µm Burnished 1,000K Cycles Ra 1.2µm Rz 7.8µm mr1 4.3% mr2 81.2% Thickness 6µm Burnished 165K Cycles Ra 0.1µm Rz 0.7µm mr1 7.1% mr2 85.7% Thickness 19.7µm New Ra 0.4µm Rz 2.7µm mr1 7.4% mr2 89.9um

Reciprocating Wear Test 2.3” Stroke, 90 cycles per min, 425 psi load, 250 F, 5W30 Castrol

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SLIDE 9

Materials & Advanced Manufacturing (M&AM)

8/10/2018 UNCLASSIFIED: Distribution Statement A. Approved for public release; distribution is unlimited

Dry Application - Turbo

  • Zero Clearance
  • Zero Friction
  • Efficiency – Throttle Response and Fuel Economy
  • Protection
  • Restoration
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SLIDE 10

Materials & Advanced Manufacturing (M&AM)

8/10/2018 UNCLASSIFIED: Distribution Statement A. Approved for public release; distribution is unlimited

Turbo Field Data

60 62 64 66 68 70 72 74 76 78 110000 115000 120000 125000 Boost (psi) Shaft Speed (RPM)

no coating 5-16 no coating 6-6 no coating 6-16 coated 7-22

  • AAPC Improved

efficiency

  • Achieved boost @ 1K-

2K lower shaft speed (red shifted left)

  • Advantage compounds

through each gear

  • Further study required
  • Courtesy of

Kevin Kwiatkowski, Kiggly Racing

Borg-Warner – Special 88 mm Turbo

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SLIDE 11

Materials & Advanced Manufacturing (M&AM)

8/10/2018 UNCLASSIFIED: Distribution Statement A. Approved for public release; distribution is unlimited

Turbo Field Data

We were out again tonight chipping away at the FWD unibody record. Every time on this slip is a new personal best! The 60' is the new 28x10.5" tire FWD record. The car went in the trailer running

  • great. We will give her a little maintenance and a

good checkup, then send it at The Shootout!

  • Kevin Kwiatkowski, Kiggly Racing
The image part with relationship ID rId3 was not found in the file.

First AAPC Runs

*Personal Best Times *60 Foot Record

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SLIDE 12

Materials & Advanced Manufacturing (M&AM)

Turbo Case – Heavy Duty

8/10/2018 UNCLASSIFIED: Distribution Statement A. Approved for public release; distribution is unlimited

Holset HD Diesel Turbocharger

  • Rotor cuts perfect seal shape during operation
  • Improves fuel economy
  • Economical retrofit
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SLIDE 13

Materials & Advanced Manufacturing (M&AM)

8/10/2018 UNCLASSIFIED: Distribution Statement A. Approved for public release; distribution is unlimited

Lubricated Application- Pistons

Improved Fit

  • APC hones piston to the ideal fit

for EACH bore

  • Permanent geometric

refinement

  • Reduces secondary motions
  • Improves ring flutter, seal and life
  • Reduces slap, noise, wear

Improved Friction

  • Break-in event seeks minimum

friction per Stribeck diagram

  • Creates uniform, stable oil film

across entire skirt

  • Enlarges contact area to spread

load and lengthen oil leak path

  • Provides long term scuff resistance
  • Tolerates foreign debris
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SLIDE 14

Materials & Advanced Manufacturing (M&AM)

8/10/2018 UNCLASSIFIED: Distribution Statement A. Approved for public release; distribution is unlimited

STRIBECK FITTING with Lubricant

Surplus Oil TurbulenceLosses

  • 1. Build tight across entire skirt.

At start-up, rapid, friendly wear-in.

  • 2. Self fitting - Oil film forms and wear rate asymptotically declines

O

  • 3. Locked-in geometry - When there is just enough room for a

stable oil film, the wear stops

  • 4. APC Piston has: a) Minimized secondary motion

b) Minimum oil film thickness for lowest friction c) No boundary lubrication Final shape is determined at temperature, under load. Friction, wear, and secondary motions of the rotating assembly are

  • minimized. Engine efficiency and durability

are enhanced. APC plateaus are polished, so a VERY THIN oil film can prevent asperity contact

14

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SLIDE 15

Materials & Advanced Manufacturing (M&AM)

8/10/2018 UNCLASSIFIED: Distribution Statement A. Approved for public release; distribution is unlimited

Uniform Contact Stress

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SLIDE 16

Materials & Advanced Manufacturing (M&AM)

8/10/2018 UNCLASSIFIED: Distribution Statement A. Approved for public release; distribution is unlimited

Stable Pistons Make More Power

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SLIDE 17

Materials & Advanced Manufacturing (M&AM)

8/10/2018 UNCLASSIFIED: Distribution Statement A. Approved for public release; distribution is unlimited

Stribeck Fitting = Less Vibration

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SLIDE 18

Materials & Advanced Manufacturing (M&AM)

8/10/2018 UNCLASSIFIED: Distribution Statement A. Approved for public release; distribution is unlimited

Stribeck Fitting = Less Noise

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SLIDE 19

Materials & Advanced Manufacturing (M&AM)

8/10/2018 UNCLASSIFIED: Distribution Statement A. Approved for public release; distribution is unlimited

AAPC in Sandy Environments

Refurbishing This piston was restored to optimum performance Protection

  • Particles embed or escape
  • No raised metal furrows
  • Core piston recoverable
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SLIDE 20

Materials & Advanced Manufacturing (M&AM)

8/10/2018

Conclusions/Recommendations

  • Since 2000, AAPC’s have been demonstrated to enhance

performance and durability of precision devices.

  • AAPC has been technically and commercially successful in

prototype, development, and automotive volumes.

  • AAPC’s have restored worn components (otherwise scrap) to

better than new performance, TBO and life.

  • The US military branches could benefit from AAPC technology

through improved readiness, performance, reduced sustainment costs, and longer life.

  • Validation on military equipment and AAPC military

specifications are needed.

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SLIDE 21

Materials & Advanced Manufacturing (M&AM)

8/10/2018

Adaptive Graphite Coatings Improve Fit and Function

  • f Pistons, Turbos and Other Precision Devices

Thank You