Automotive and motorsport

Automotive and motorsport - coating The entire performance spectrum is of the greatest importance in the automotive industry; the reduction of servicing intervals, enhancement of performance and the use of cheaper substrate materials are only a few examples. Benefits in the power train and in engine technology are especially great. Surcoatec coatings are used both in series production of cars and commercial vehicles and on many high-performance components in motorsport.

Example: The piston/cylinder system

coating technology: The piston/cylinder system

The assignment

Development of a friction-reducing coating not less than 5 µm in thickness for the inner wall of cylinder liners and a friction-reducing outer coating for the piston rings.

Objective

  • Reduction of friction
  • Reduction of wear
  • Greater performance
  • Weight reductions via the use of alternative materials (e.g. CFRP cylinder liners)

Result

  • An 8 µm thick multi-layer DLC coating was applied for the first time ever in a hollow chamber
  • Enormous friction reductions confirmed
  • Coating thickness has also been verified, thus permitting the use of alternative liner materials

» Coating recommendations: DC99-A®, DC99-C®
 

Example: Ball pin in a motorsport steering system

Ball pin in a motorsport steering system

The assignment

Development of a coating to reduce the coefficient of friction on a hemispherical pin for the steering rod (Material: MP35N - 35% nickel, 35% cobalt, 20% chromium, 10% molybdenum)

Objective

  • Easier operation thanks to lower friction
  • Reduction of wear

Result

  • Coating of only one element of the friction pair reduced the coefficient of friction by 50%. Further reduction by coating the other element is now planned.

» Coating recommendations: DC99-C®
 

Example: Engine components

Example: Engine components

The assignment

Development of a coating to increase the hardness of tappets and reduce friction with the camshaft. Tappets consisting of a new aluminium alloy were also coated in parallel as an alternative to the steel material currently used, in order to achieve a reduction in weight.

Objective

  • Hardness greater than 3,000 HV
  • Application of a layer of not less than 2 to 3 µm
  • Bond strength of HF1 to HF3 in accordance with VDI 3198
  • Unchanged surface roughness

Result

  • The above targets were achieved on both steel and aluminium tappets
  • Combination with the Surcoatec coating permits a changeover to aluminium, and thus useful weight-savings

» Coating recommendations: DC99-A®