The heat is off Wayne Ward explains how to use coatings to help improve engine and vehicle performance – without necessarily burning more fuel W hen the subject of coatings was last covered in these Formula One with exhaust heat and kinetic energy recovery. The car pages, in 2010, most of the coatings in widespread manufacturers involved wanted an engine formula that reflects a high- use now were already commercially available. tech approach to efficient motoring, and despite the performance and What has perhaps changed most since then though reliability of modern Formula One engines, the manufacturers have no is the fact that coatings are now more commonly considered at the appetite to continue along a technological dead end. MotoGP notably design stage. Having proven their worth in the past few years through has increased engine capacity, but mandates an ever-decreasing experiment and in solving specific problems, more recent components quantity of fuel for the race. Witness riders running out of fuel for are likely to incorporate coatings from the outset. evidence that more work is required on efficiency. Regardless of whether you believe in global warming or that our fossil fuel resources are close to being exhausted, it has become clear The development of coatings for motorsport with the sole purpose of that these issues can not be ignored; greenhouse gas emissions are the decreasing friction has advanced the technology to the point where subject of a great deal of legislation, and gasoline prices worldwide production car manufacturers can justify using in a cheap engine a keep rising. The result is a concerted drive for more fuel-efficient coating that, ten years previously, would have been the preserve of the vehicles. As far as the car companies are concerned, a happy customer better-funded Formula One teams. is a returning customer, and currently a car with low fuel consumption The ongoing battle to increase vehicle efficiency means that not makes a lot of customers happy, so it has become the policy of car only is powertrain efficiency important, aerodynamics have a role to manufacturers to supply cars that are economical. play too. Of course, on the powertrain side, we can use coatings to Race series have a responsibility to reflect motor manufacturer influence efficiency, the most obvious way being to reduce friction. Yet policy. That is not to say they are under an obligation, but if race aerodynamics have a huge influence on the performance and efficiency series organisers wish to be supported by motor manufacturers at of a vehicle as well: low-drag vehicles need less power to propel them the top levels of the sport, the series rules need to match the policies at a given velocity. Equally, for a given power output from an engine, the and aspirations of the motor companies. Although Audi for example top speed will be higher where a vehicle has reduced drag. probably doesn’t have a ready market for 800 hp V10 diesels, it 30 Coatings are an integral part of this search for increased efficiency. All very interesting, you may say, but how are you able to play your has made great marketing capital from its race diesel project, and part in this aerodynamic aspect of vehicle performance? Well, the greater continues to do so. Clean, quiet, efficient: just what customers want. the heat rejection, the greater the cooling requirements, and with that In addition, 2014 will bring 1.6 litre V6 turbocharged engines to comes the need for larger coolers, which come with an aerodynamic FOCUS : COATINGS Fig. 1 – Shell bearings have thin metallic coatings as standard. These have had a further dry-film lubricant coating applied (Courtesy of Swain Tech Coatings) penalty. So we need to consider not only coatings for mitigating have led to components becoming smaller. Despite smaller components powertrain friction, we also need to consider heat management. and bearing diameters, we still have high speed differences at sliding You may be tempted to think that this aerodynamic penalty applies contacts, and while we try our best to provide rolling-element bearings, only to single-seater cars, where bigger coolers require bigger journal bearings or lubrication wherever possible, friction still accounts sidepods. In the case of single-seaters, to equate larger sidepods to for a lot of the energy wasted in an engine. larger coolers seems intuitive. In closed cars though, even in the Shells for journal bearings are a prime example of a coated case of production-based cars where the cooling ducts and coolers component. These can have a number of coatings, but if we take the are within the vehicle’s volume, increased air cooling requirements example of a tri-metal bearing, the steel shell has two coated layers, have an associated drag penalty. In NASCAR, for example, there is a both of which are metallic. The first is a relatively thick coating of a significant penalty associated with the need to provide a large factor of copper alloy, usually alloyed with lead and tin. This layer is about safety on the cooling, in case a cooling duct becomes blocked by litter 0.25 mm (0.010 in) thick and provides a support for the thin plated carelessly discarded by a race fan. Being close to the action is great, overlay at the bearing surface. Besides supporting the bearing surface, but such carelessness has affected the performance of these cars, and the copper alloy intermediate layer has a number of important roles, therefore their design. particularly in providing a degree of compliance at the edges of the The previous article in Race Engine Technology on coatings (1) took bearing and giving the bearing ‘embeddability’, the term given to the a ‘tour’ around an engine, and pointed out the coating options for each bearing’s capacity to cope with small particles of debris within the oil component. Given the relatively recent focus on performance with delivered to the journal bearing. efficiency, this article will look at some of the important factors such as The overlay has a very low shear strength and is also very thin. friction, wear and heat management, and will examine how design and Overlay materials can vary, but alloys of lead and indium are development engineers can use coatings to help improve engine and commonly used in racing. To maintain the shape and form of the vehicle performance without necessarily burning more fuel. bearing, and minimise friction, the overlay is kept very thin to prevent excessive deformation under load and keep the contact area to a Friction and wear minimum. The combination of low shear strength and low contact There are many sources of friction in an engine and transmission. With area provide low friction during those short periods of time where full so many moving components, it is impossible to avoid heavily loaded hydrodynamic lubrication has yet to become established. A number of coating companies also offer polymer-based coatings on of components in contact. With the passage of time, engine speeds have top of the bearing shell overlay coating [Fig. 1]. These are marketed as increased, and attempts to reduce mass and mitigate frictional losses dry-film lubricants to help when lubrication is poor, such as at engine t sliding contacts. From the top to the bottom of the engine, we have pairs 31 FOCUS : COATINGS At two points in each cycle, when the point of contact between cam and follower is close to the nose of the cam lobe, the entrainment velocity drops to zero. If you plot a graph of valve velocity, the two points in the cycle occur very close to the maximum valve velocity. Where the valve velocity is at a maximum, the point of contact between the follower and cam has stopped moving. At each of these points, we have a large load to support, but there is nothing to generate any pressure in the oil film – there is no hydrodynamic lubrication – and the oil film is then subject to squeeze-film lubrication. Away from these points, where the entrainment velocity is low, the oil film is stable but has very low thickness. Where the thickness of the oil film approaches the height of the surface texture on the Fig. 2 – Camshafts and cam followers are very commonly coated with DLC or one of its derivatives (Courtesy of Diamond Hard Surfaces) component, high points called asperities on each surface can come into contact. At this point, we start to experience the mixed or boundary lubrication “A thick CrN under the DLC will enhance the loading capacity” regime, whose coefficient of friction is a function of the hydrodynamic lubrication and the dry coefficient of friction between the materials involved in the contact. In such situations, a low coefficient of friction is very desirable, as are smooth surfaces. The lower the surface finish height, the shorter the period during which mixed lubrication applies, and a low coefficient of friction between the parts in contact ensures that when mixed or boundary lubrication exists, the frictional losses are mitigated. As mentioned, DLC coatings have been successfully applied to camshafts [Fig. 2] and cam followers, but the choice of which ‘flavour’ start-up, when there are oil system problems or where the operating of DLC to use is not straightforward, so experience is required here, conditions of the race vehicle cause oil starvation. Cars exploiting as this has a significant impact on the friction and wear behaviour downforce over hills or bumps have proven susceptible to a lack of oil of the contact under boundary lubrication conditions (2). Also, by at the oil pump pick-up, and any car where there are significant lateral their composition, DLC coatings can affect the interaction of the anti- forces due to cornering can also suffer from such problems. wear additives in the lubricant with the uncoated component in the have been made much more reliable by using modern coatings measurable on a full engine dyno, and will definitely be measurable technology. The cam-to-follower contact is one that has been on a cylinder head dyno. While the frictional gain is certainly particularly improved by the use of low-friction coatings. Diamond- worthwhile, hard coatings have also allowed the use of higher contact like carbon (DLC) coatings and their derivatives have been especially stresses between cam and follower. This means that higher forces successful in such applications. DLC is not one coating but a large may be used in the system, paving the way for higher levels of valve family of coatings. They are very often not purely a carbon coating acceleration and therefore allowing performance engineers greater but have significant proportions of other elements in order to tailor latitude in the development of valve-lift profiles. their properties, and they have a range of possible structures, from Other than the cam-to-follower contact, the use of coatings to amorphous to crystalline. Carbon coatings within the DLC family can mitigate frictional losses in the valvetrain is limited mainly to valve have a mixture of graphite and diamond-type bonds; very often these stem coatings [Fig. 3, page 34]. These are commonly one of the coatings also contain hydrogen and, less commonly, the coatings are thin, hard coatings, and DLC competes with other coatings such ‘doped’ with metal ions to fine-tune their properties. as chromium nitride (CrN) and titanium nitride (TiN). On titanium The contact stresses in the cam-to-follower contact are extremely valves, companies responding to questions for this article said DLC on high, and the intention is for the contact to be operating in the titanium often requires another coating, an ‘underlayer’. One supplier elastohydrodynamic lubrication regime. The theory and equations of said, “A thick CrN under the DLC will enhance the loading capacity.” elastohydrodynamic lubrication are beyond the scope of this article, Valve coatings that can increase temperature resistance, such as but there is some value to expanding on them a little. The conditions for lubrication are influenced by ‘entrainment velocity’ which is the algebraic sum of the velocities involved in the contact. 32 contact (3). The gain from running new DLC-coated followers might be TiAlCrN, will probably become more important as the temperature of combustion products continues to rise. While the loads in the valveto-guide contact are low, the intermittent nature of the valve action t There are a number of highly stressed contacts in the engine that DLC CERTESS COATINGS ® HEADQUARTERS AND R&D: FRANCE http://hef-group.com Tel : + 33 (0)4 77 55 52 22 [email protected] Sales units and contacts: EUROPE Tel: +33 4 77 55 52 22 [email protected] USA, CANADA Tel: +1 937 323 25 56 [email protected] GERMANY, AUSTRIA Tel: +49 621 32 224 0 [email protected] CHINA Tel: +86 21 6487 4390 [email protected] CZECH REPUBLIC Tel: +42 07 24 91 38 37 [email protected] INDIA, PAKISTAN, BANGLADESH Tel: +91 984 102 3772 [email protected] SOUTH AMERICA Tel: +55 11 4070 7236 [email protected] JAPAN, KOREA, TAIWAN, VIETNAM Tel: +81 45 474 2844 [email protected] MEXICO Tel: +52 442 298 0429 [email protected] OTHER COUNTRIES Tel: +33 4 77 55 52 22 [email protected] High-performance coatings and a wealth of experience in the surface engineering sector makes a huge difference to: Minimize friction losses, decrease wear and improve performance. Extensive knowledge of surface engineering, interactions and failure-mechanisms allow us to provide solutions to the most demanding applications. RET_ADTEMP.indd 1 22/06/2012 16:54 FOCUS : COATINGS means lubrication of the contact is rather less than ideal; the low friction coefficient minimises adhesive wear of the guide. In race series that allow pneumatic valve return Fig. 3 – These valves are DLC coated; this reduces friction between stem and guide, and seat wear can also be greatly reduced (Courtesy of Industrial Hard Carbon) systems (PVRS, or air springs as they are sometimes called), the bore in which the pneumatic systems operate is often coated to reduce friction and mitigate seal wear. Formula One and MotoGP, which both have high engine speeds, use PVRS systems. The use of coatings on pistons and rings has been common for a long time. Piston rings for racing have progressed from hard metal-sprayed coatings such as molybdenum to the hard, thin coatings such as DLC and TiN. The motion of the piston is reciprocating and there are two points at which the piston and its rings come to a halt – top dead centre (TDC) and bottom dead centre (BDC). Again, we have a contact where the conditions for full hydrodynamic lubrication are not met throughout the operating cycle. As far as rings are concerned, the change to thin, lowfriction coatings has a number of benefits compared to the older sprayed metal coatings. Their most attractive property as a ring low friction and so is used in much the same way as the resin-bonded coating is reduced friction, which is of direct interest to the design polymer coatings. There is one piston company that is noted for its engineer and development engineer alike. The lower coefficient use of resin-bonded graphite coatings on piston skirts, and it has of friction allows some latitude in how the advantage is best used. gone further by introducing a ‘tread pattern’ into the coating for some Frictional losses can be reduced compared to a sprayed ring if the applications, which it says enhances dynamic oil control. is DLC. There have been several barriers to the use of DLC for piston old sprayed coatings were a labour-intensive process that required skirts until relatively recently. Initially, the processing temperatures machining after coating, but the modern engineering coatings are required precluded its use for aluminium and a number of steels that very thin and repeatable, so no post-coating machining is required. temper at low temperature. In solving this problem for materials such Coatings such as TiN and DLC are also less susceptible to wear. as carburising steels, the use of DLC on aluminium has become more As regards piston skirts, there are a wide range of coatings with the realistic. However, the simple application of DLC to an existing piston aim of, or that have the effect of, reducing frictional losses and wear. is likely to create serious problems, and it has taken piston makers There are four main types of coating used here – hard engineering some time to develop piston machining to the stage where the piston coatings, polymer/resin coatings, graphite-based coatings and does not simply become a reciprocating file. phosphating. Phosphate-based coatings are aimed essentially at improving the If we were to take an optimised DLC-coated piston and examine it alongside a similar but conventional uncoated piston, the running-in of the piston in the bore when the engine is initially run. difference would be striking. One such optimised piston was shown They are not especially low friction in themselves, but owing to the oil in a previous article (5), and the machining can easily be seen retained in their porous structure, they are a popular choice to provide to be much smoother than would be found on a conventionally increased lubricity. They are very thin and provide neither compliance machined piston skirt and ring lands. DLC-coated pistons need to nor a surface that can wear into shape. have a very well optimised skirt profile so that no wear-in of the Polymer/resin coatings have been applied to racing pistons for skirt is necessary. The DLC coating is not prone to wear, and areas decades. They are aimed at both friction reduction and improved that are too heavily loaded are likely to see the coating damaged, running-in behaviour. The coating consists of a low-friction polymer with hard debris possibly produced as a result. Owing to the low such as PTFE in a resin binder. They are applied and cured at low strength, low stiffness and high ductility of the aluminium substrate, temperatures, making them suitable for use on aluminium pistons. the low-ductility coating simply cracks under high local loads as They make a useful contribution to friction reduction and have a the substrate deforms. The adhesion of DLC to aluminium can be thickness that allows them to wear into a shape that suits the use of affected by the specific treatment used, the composition and any the engine. This is not a new concept: thick resin composite coatings pre-treatments – for example, micro-peening with silicon carbide has have been used in the past (4) for piston skirt profile development; the been proved to increase adhesion and maintain low friction for DLC coating wears into a shape that is then ‘reverse engineered’ to make on aluminium alloys (6). the production piston. A similar coating is resin-bonded graphite. Graphite is noted for its 34 The most recent anti-friction coating to be developed for pistons to improve ring sealing, with no increase in frictional loss. The One company has developed a coating based on anodising, and is treating pistons. The porosity in the aluminium oxide structure of the t same ring tension is maintained, or ring tension can be increased Nitron™MC / Nitron™ Lubrica Coated Gears Tribological Treatments for High Performance Engine and Structural Components Standard and customised surface coatings meeting demanding application duties; Technologies on site Include: • Surface Preparation and Polishing • E- Beam PVD [TiN, CrN , Nitron™CA] Magnetron Sputtered [Nitron™MC WC-C and CrN] • PECVD [Multi Layer DLC] • InnerArmor™ HCIIP DLC coatings of Internal Bores • Nitron™Lubrica [WS2 dry lube) • Ion Implantation • Duplex Nitron™ O treatment for Titanium Alloys and Stainless Steel • Research and Development Laboratories. • Machine Build / Modification Engineering Tecvac Ltd, Buckingway Business Park Swavesey, Cambridgeshire CB24 4UG, UK • Tel: 01954-233700 • Fax: 01954-233733 • www.tecvac.co.uk • e-mail: [email protected] RET_ADTEMP.indd 1 22/06/2012 16:56 FOCUS : COATINGS anodising is impregnated with ceramics to provide improved wear Fig. 5 – Coated gears aimed at low friction can also offer short-term protection against lubrication failure (Courtesy of Oerlikon Balzers) resistance [Fig. 4]. The rest of the cranktrain has also been subject to much investment in terms of coatings, which are often applied to piston pins and con rods, although these applications are aimed mainly at wear prevention rather than frictional losses. The application of coatings to crankshafts is so rare that there is no good data available to judge the success of hard coatings in reducing friction. However, when writing a crankshafts article in 2010, two crankshaft suppliers admitted to me they were offering DLC-coated crankshafts commercially (7). Low-friction, hard coatings can offer an advantage for gears where lubrication is marginal, and may offer some protection against failure due to loss of lubrication where the oil is being lost from a gearbox or cam drive casing. Coated gears have proved more durable than uncoated gears in tests conducted by NASA (8). The applications of coated gears for motorsport are mainly in transmissions [Fig 5]. the heat produced and how we manage unwanted heat can all affect the performance of the car or bike over the course of a race. Coatings Managing heat for car performance can play a significant part in improving this performance. We can use Heat is something that internal combustion engines produce in great them to improve volumetric and combustion efficiency, improve the quantities. Very roughly, 30% of the energy contained in the fuel efficiency of the turbocharger assembly and decrease the amount of burned in a typical passenger car engine is turned into useful work heat rejected to the oil and water systems on the car. at wide-open throttle. Throttling in gasoline engines reduces this In terms of combustion, we can improve the efficiency of fuel efficiency. The remaining 70% has to go somewhere, and as you will conversion by rejecting less heat from the combustion chamber. This be aware either from experience or a knowledge of physics, it is turned can be achieved by increasing the thermal resistance of the combustion into heat. This heat exits the engine in small quantities by radiation, chamber walls. In practical terms, we do this by using materials with but very largely through the exhaust port or into the oil and water lower thermal conductivity. However, low-conductivity walls mean systems. We have to reject all of this heat to the atmosphere. high wall temperatures, and high wall temperatures do not help cylinder Heat is a by-product of combustion that is largely wasted. filling. Low-conductivity walls also mean that we probably need to look Production cars use a little of it for cabin heating but, beyond this, only to materials other than aluminium alloys, which are known and loved for turbocharged engines benefit from lots of heat being produced. Ideally, their high thermal conductivity and low density. we would like the chemical energy stored in the fuel to be converted An engine that keeps heat in the combustion chamber would be into work with no heat generated. How successful we are as engineers a heavy engine. Coatings can help in this regard, by making our in optimising the conversion of chemical energy into heat, how we use lightweight aluminium engine components behave as if they were made from something less thermally conductive. A thin layer of Fig. 4 – This piston has been anodised and then the porous structure thus created has been impregnated with ceramics to provide a very hard-wearing surface (Courtesy of Tech Line Coatings) an insulating coating is very effective as a thermal insulator, and a number of companies we spoke to for this article are involved in the subcontract coating of race engine components for this purpose. The coatings need to be highly insulating, very thin and preferably have low density. Many of them are based on metal oxides and, if they are working properly, will get very hot. If they are too thick, and have too high a mass, they will heat the incoming charge, causing it to expand, and this can lead to serious losses of volumetric efficiency. What we want to happen is for the mass of the hot coating material to be so small that the incoming charge cools it with little heat transfer. A further disadvantage of the charge temperature increasing is the likelihood of knock occurring. Knock is uncontrolled combustion, and can lead to serious damage and even catastrophic failures of the engine. In the interests of reliability, knock is best avoided, although some engines are known to give their best performance at the onset of knock, or even during ongoing knock. Highcompression gasoline engines are known to be prone to knock, as compression. Although real race engines don’t conform to the ideal 36 t pre-combustion temperatures are higher than in engines of lower IBC Coatings Technologies, INC offers a wide range of unique high performance coatings and surface treatments: • Low friction Vanadium carbide – TDC+™ (valves, bearings, gears, actuators, blades) • Ion Plasma Nitriding – DHIN+™ (crankshafts, springs…) • More than 10 different types of Diamond like coatings DLC+™ (gears, pins, valves, stems, camshafts, spindles, bearings) • Thermal Diffusion ceramic coating CERATOUGH™ for Aluminum, Titanium, Magnesium, Steel, Nickel alloys… (Pistons, Housings, Cylinders) • Abrasion, erosion and corrosion resistant Boriding – DHB+™ , Chromizing –DHC+™ (Pumps, Actuators…) • Low temperature wear, and corrosion resistant surface treatments of stainless steels DHINS+™ Surface engineering developments are available per customer demand. Solomon Berman, Ph.D. IBC Coatings Technologies, INC, 902 Hendricks Drive Lebanon , IN 46052 Phone: 765-482-9802, Fax: 765-482-9805 E-mail: [email protected], www.ibccoatings.com RET_ADTEMP.indd 1 22/06/2012 17:12 FOCUS : COATINGS properties and resistance to thermal shocks Fig. 6 – Coating the surfaces of the combustion chamber, including the piston crown and valve faces, reduces heat rejection. Note also the coated ports at the back of the exhaust valve head (Courtesy of Swain Tech Coatings) that ceramics have, and they aren’t subjected to rapidly fluctuating pressures. Both polymer coatings and ceramic coatings can be used to good effect in inlet systems. Exhaust systems, and the management of heat transfer within and from them, is one area where coatings can make a huge difference. The return of the turbocharger to top-level racing makes the management of exhaust heat more important. There are two reasons for the significance of effective thermal insulation and prevention of radiated heat with turbocharged engines. First, the turbine becomes more efficient if the turbine inlet temperature is higher. Second, owing to the fact that more charge is burned within a turbocharged engine of given capacity compared air cycle, they do show the same trend in terms of cycle efficiency to a naturally aspirated engine running at the same speed, the exhaust versus compression ratio – that is, a higher compression ratio gives gas temperatures and flow rates are very much higher. Consequently, the increased efficiency – so there is a tendency to use engines with high heat transferred from the hot exhaust system to its surroundings needs to compression ratios. Turbocharged and supercharged engines are be more carefully managed in a turbocharged car. particularly prone to knocking combustion, especially where ambient Keeping heat within the exhaust gas not only gives benefit to a temperatures are high and where post-compressor charge cooling is turbocharged engine, although turbocharged engines do benefit poor. Metallic coating of piston tops has been proved over many years most from effective thermal insulation. The first place where the to protect piston crowns from the damage associated with knock (9). engineer can look to minimise heat transfer is within the engine itself, If we add a thermal barrier coating to the top surface of the piston, and reduce heat transfer via that route, other surfaces that are not specifically the exhaust port. We will assume that as much heat as possible has been retained treated in the same way will be subject to increased heat transfer, within the combustion chamber. There are a number of design features as the temperature in the combustion chamber will be increased. that can be incorporated into an exhaust port to minimise heat transfer We might expect to find that people are coating other combustion to the water jacket, but coating with a thermally insulating material chamber surfaces, and indeed a number of coating companies offer a is an effective method. For naturally aspirated engines, reduced heat service to coat the combustion chamber surfaces in the head and the transfer to the coolant is the only real benefit of an insulated exhaust flat faces of the valves which see combustion [Fig. 6]. port as it allows the use of a smaller cooler, with the attendant benefits A lot of work was done on adiabatic and ‘low heat rejection’ engines of reduced aerodynamic drag. By keeping the heat in the exhaust between the late 1970s and early 2000s as car companies sought to gases, we can expect the exhaust system to run hotter. This transfers develop more efficient engines. Engines that were not required to have heat to its surroundings by radiation, convection and conduction. We any cooling circuit were believed to be highly desirable, especially for can minimise conduction between the exhaust system and the cylinder military applications, where cooling ducts and grilles are weak points head by using thermal barrier coatings on the mating face of the on such vehicles. Much of the work centred on developing thermal exhaust or cylinder head if there is direct contact. barrier coatings for use in combustion chambers. Similar materials and Coating the exhaust system itself is a process offered by a number of processes developed then (10) are still used these days for thermal barrier applications. There is a lot of good data, such as the paper by Civiniz et al (11), on the positive effects of thermal barrier coatings on combustion chamber surfaces, which has been generated through the work carried out on engines with low heat rejection. There are a number of low thermal conductivity coatings that can be used in the inlet system of a race engine to insulate the system’s components from heat generated in the combustion chamber. A cooler inlet means higher charge density, and this is good for cylinder filling. Unlike combustion chamber coatings, those used on inlet system components do not need to have the high-temperature 38 Fig. 7 – Coating the exhaust headers and turbine housing can improve the turbocharger’s transient response (Courtesy of Swain Tech Coatings) companies I contacted when researching this article. Again, insulating ‘thermal barrier’ coatings are used here, based on ceramics [Fig. 7]. For turbocharged engines these have the dual benefits of retaining heat within the exhaust system in order to improve turbine response, and mitigating the effects of radiated heat on the surrounding components. So popular is ceramic coating of exhausts that such coatings are offered in a range of colours! While ceramic exhaust coatings are effective in reducing exhaust heat radiation, they cannot by any means be said to prevent it. There are a number of reasons for minimising the radiation of heat from the exhaust to adjacent components, but two that will be of real interest to engineers are performance and reliability. It is turbocharged engines that benefit from the retention of heat within the exhaust, as we have discussed, and it can be argued that there is a performance disadvantage with retaining heat within the exhaust of a naturally aspirated engine. The time taken for a wave to travel to the end of the exhaust system (or a pipe junction within the exhaust) is a function of the speed of sound within the gas in which the wave is propagated. Within a gas of fixed composition, the speed of sound increases with the square root of absolute temperature. Therefore, for a highly optimised exhaust system, any pipes making up the system would need to be slightly longer to provide the same tuning response as the non-insulated exhaust. However, the difference in length would be extremely small, and it is unlikely that anyone driving a car equipped with an exhaust system with a thermal barrier coating would notice any difference. For a 10 C exhaust gas temperature difference for an 800 C exhaust gas temperature, the length of a 1000 mm exhaust system would need to increase by less than 0.5% in order to maintain the same time interval between a pressure wave leaving the exhaust valve and the corresponding reflected wave arriving back. The effect of retaining heat within the exhaust can have a noticeable effect on performance of the vehicle for other reasons. A hot exhaust can transfer heat by radiation and convection to the inlet system, engine casings and transmission. The rate of heat transfer to the inlet system can increase inlet charge temperature, and this has a negative effect on the trapped charge mass within the cylinder, and hence on performance. Where heat is transferred to the engine and transmission cases, it will naturally have to be removed through increased cooling. As already mentioned, increased cooling requirements affect aerodynamic drag on the vehicle. The effect of reducing heat transfer on reliability is a real effect but one that is not easy to quantify, although it is one that many will understand the logic of. High temperatures affect the mechanical properties of materials. In some cases, modest increases in temperature above ambient will improve tensile strength. However, many of the external components of a typical race engine will be made from materials such as aluminium, which definitely do not benefit from being run at high temperatures. Also, with the widespread use of electronics comes the use of soldered connections, and sensors, actuators and various other boxes of electronics can be seen to fail at Aerodynamics play a large part in determining the packaging of 30-42 COATINGS (v.GR).indd 39 t low mileage without sufficient protection from heat. 22/06/2012 15:50 FOCUS : COATINGS the components within the engine bay. As a result of this, hot parts definitely more suited to your particular application than others. You are forced into close proximity with those that need to be protected should take time to avail yourself of the facts, and seek the advice from heat. Thermal barrier coatings on exhausts are one part of the of the coating companies and their in-house expertise. Make sure solution here, but the use of heat shielding is also important to provide you know your facts, to prevent being seen as ‘the salesman’s dream a physical barrier to radiated heat. Coatings are applied extensively to customer’. Many of the reputable suppliers will give good advice, heat shields, either as thermal insulation or as a reflective layer. and will even point you to solutions to your problems from other Heat transfer by radiation is a function of the fourth power of the companies if their particular product doesn’t suit your application. As temperature difference between the emitting and absorbing bodies, one company we spoke to put it, “Where we offer a helpful coating and is directly proportional to a property of the absorbing body known solution we offer it, but if there is more appropriate technology as emissivity (also sometimes called absorbance or absorptivity). We available from others we make prospects aware of those options.” would like our heat shields to provide a combination of reflectivity to prevent thermal radiation directly reaching the components that might References suffer reliability problems without themselves reaching a high enough 1. Ward, W., Focus article on coatings, Race Engine Technology, issue temperature to become an efficient emitter of thermal radiation. In 47, June/July 2010 cases where no steps are taken to isolate the engine from the effect 2. Erdemir, A., “Friction and wear of diamond and diamond-like carbon of exhaust heat, and where oil/water/air cooling cannot be increased, films”, Proc. ImechE, Part J, Journal of Engineering Tribology, 2002 we have to accept that coolant temperatures – and, as a consequence, 3. Renondeau, H., Taylor, R.I., Smith, G.C., and Torrance, A.A., internal component temperatures – will be increased. “Friction and wear performance of diamond-like carbon and Cr-doped Some coatings are marketed with the stated aim of increasing heat diamond-like carbon coatings in contact with steel surfaces”, Proc. dissipation. Unfortunately, there is very little good quality, comparative ImechE, Part J, Journal of Engineering Tribology, 2008 data concerning these coatings for automotive applications, although 4. Yagi, T., and Yamagata, I., “Experimental Method of Determining Piston there are some bold claims made regarding improved performance of Profile by Use of Composite Materials”, SAE Technical Paper 820769 coolers treated with such ‘thermal dispersion’ coatings. 5. Ward, W., Focus article on pistons, Race Engine Technology, issue There are two mechanisms by which coatings can increase the 43, December/January 2010 ability of a surface to transfer heat to the atmosphere. The first is to 6. Amano, Y., Nanbu, H., Kameyama, Y., and Komotori, J., “Tribological increase the surface area of the cooler; in this case the coating turns Properties of Aluminum Alloy treated by Fine Particle Peening/DLC the surface into a very thin heat sink. While there are a number of Hybrid Surface Modification”, Proc. 14th International Conference on paints and powder coatings that are ‘wrinkle-finish’ it would be Experimental Mechanics, 2010 very easy to take a step backwards here if the coating itself has a 7. Ward, W., Focus article on crankshafts, Race Engine Technology, higher thermal resistance than the bare metallic cooler. The second issue 49, September/October 2010 mechanism is to process a cooler with a coating that combines high 8. Krantz, T.L., Cooper, C.V., Townsend, D.P., and Hansen, B.D., heat capacity and high thermal conductivity. Such coatings have been “Increased Surface Fatigue Lives of Spur Gears by Application of a specifically developed for the cooling of electronics, as described in Coating”, NASA/TM-2003-212463 the paper by Stappers et al (12). These coatings are engineered to take 9. Towers, J. M., and Hoekstra, R. L., “Engine Knock, A Renewed large amounts of heat into the surface of the coating and then allow Concern In Motorsports – A Literature Review”, SAE Paper 983026 rapid conduction to cooler parts of the surface. 10. Bose, P. K., Beg, R.A., Saha, S.K., Ghosh, B.B., Das, S.K., and The coatings as described by Stappers et al are very specialised and Majumdar, A., “Glass Ceramic Coating – an Alternative to Plasma Spray are developed to use the transition between solid and liquid states for Internal Combustion Engine Components”, SAE Paper 2000-01-2918 of particles trapped within the coating. They are therefore aimed at 11. Ciniviz, M., Hasimoglu, C., Sahin, F., and Salman, M.S., “Impact of removing heat at very specific temperatures. Coatings with improved thermal barrier coating application on the performance and emissions surface conduction could be made by using metallic coatings with of a turbocharged diesel engine”, Proc. IMechE, Journal of Automobile similar combinations of properties. Silver is a possible candidate here, Engineering, 2008 as it is highly thermally conductive and has a high heat capacity. 12. Stappers, L., Yuan, Y., and Fransaer, J., “Novel Composite Coatings Summary 152, 2005 Where we are looking to maximise engine output by reducing friction and managing heat more effectively, looking to make the engine CREDITS installation more reliable by shielding vital components from excess The author would like thank the following for their assistance: Linda Stappers of Katholieke Universiteit Leuven, Domenico Magnacca of Sulzer Metco Europe, Richard Tucker of Swain Tech Coatings, Franck Derangere of Ionbond PVD France, Toby Middlemiss of Oerlikon Balzers, Carrie Bordeaux of Industrial Hard Carbon, Chris Osborne of Tecvac, Chris Walker of Diamond Hard Surfaces, Leonard Warren of Tech Line Coatings and Hitoshi Kawai of Miyaki USA/Kashima Coat. heat, attempting to improve turbocharger response by retaining heat energy within the exhaust flow, or trying to minimise heat rejection to water and oil in an attempt to reduce cooling requirements, coatings can help. There is a wide array of coatings on the market, and some are 40 t for Heat Sink Applications”, Journal of The Electrochemical Society, vol Run cool, look even cooler. Our high performance ceramic exhaust and engine coatings will help you do just that. We’re not called PERFORMANCE COATINGS for nothing! For more information please call us on +1 253 735 1919 or visit www.performancecoatings.com PERFORMANCE COATINGS 60 - 37th Street NE, Auburn, WA 98002, USA HARD CARBON COATINGS AND ENGINEERING SOLUTIONS FOR MOTORSPORT APPLICATIONS BY 1-866-5-RAPTOR www.CarbonRaptor.com www.IndustrialHardCarbon.com RET_ADTEMP.indd 1 22/06/2012 16:58 FOCUS : COATINGS SOME EXAMPLES OF COATING SUPPLIERS AustriA Zzuhl Ltd. ZN +43 125 33033 1694 FrANCE HEF Group +33 47 75 55 222 sulzer Metco +33 55 53 70 490 www.zzuhl.com www.hef.fr www.sulzer.com GErMANY Axyntec +49 8217 4999140 www.axyntec.de EsK Ceramics +49 8315 6180 www.esk.com Kexel Motortechnik +49 2663 6823 www.kexel.de systec sVs Vacuum Coatings GmbH +49 9353 79030 www.systec-vacuum.com itALY Breda Coatings +39 0261 543911 Lafer spA +39 0523 517940 sulzer Metco +39 0290 39241 www.rtmbreda.it www.lafer.eu www.sulzer.com NEtHErLANDs Hauzer techno Coatings +31 77 355 9777 www.hauzer.nl sWitZErLAND ionBond +41 62 287 8686 sulzer Metco +41 56 618 8181 www.ionbond.com www.sulzer.com n uK Anochrome Group +44 (0)1902 567567 www.anotec.co.uk Camcoat Performance Coatings +44 (0)1925 445688 www.camcoat.com Diamond Hard surfaces +44 (0)1327 354330 www.diamondhardsurfaces.com Dynamic Ceramic +44 (0)1270 501000 www.dynacer.com E/M Coating services +44 (0)1252 523000 www.eltro.co.uk Hardide +44 (0)1869 353830 www.hardide.com Materials & surface Engineering Ltd +44 (0)7958 077234 www.mat-surf-eng.com Motrac racing +44 (0)151 357 1062 www.motrac-racing.com Oerlikon Balzers +44 (0)1908 377277 www.oerlikon.com surface technology +44 (0)1294 211988 www.surfacetechnology.co.uk tecvac +44 (0)1954 233700 www.tecvac.com teer Coatings +44 (0)8702 203910 www.teercoatings.co.uk Ws2 Coatings +44 (0)1430 861222 www.ws2.co.uk Zircotec +44 (0)1235 434320 www.zircotec.org.uk Zzuhl Ltd +44 (0)1422 230203 www.zzuhl.com usA AirBorn Coatings +1 704 483 5000 www.airborn.cc Armoloy of Western PA +1 610 751 5111 www.armoloy-wpa.com Calico Coatings +1 888 236 6079 www.calicocoatings.com Caps Brite Hot Coatings +1 559 233 1461 www.capsbhc.com Central Connecticut Coatings +1 860 528 8281 www.centralctcoatings.com Embee Performance +1 714 546 6907 www.embeeperformance.com Finishline Coatings +1 503 659 4278 www.finishlinecoatings.com Hekimian racing Engines +1 617 926 0608 www.hekimianracing.com HM Elliott +1 704 663 8226 www.hmelliottcoatings.com iBC Coating technologies inc +1 765 482 9802 www.ibccoatings.com industrial Hard Carbon (Carbon raptor) +1 704 489 14889 www.industrialhardcarbon.com ionBond +1 973 586 4700 www.ionbond.com Jet Hot Coatings +1 336 447 2028 www.jet-hot.com Keco Coatings +1 800 336 5326 www.kecocoatings.com Lincoln Performance Coatings +1 402 475 3671 www.lincolnindustries.com Micro surface Corporation +1 800 248 4221 www.microsurfacecorp.com Miyaki Co., Ltd us Office +1 310 755 5160 www.kashima-coat.com Morgan Advanced Ceramics +1 610 366 7100 www.diamonex.com NiC industries +1 541 826 1922 www.nicindustries.com Nitroplate +1 615 826 4914 www.nitroplate.com Northeast Coating technologies +1 207 985 3232 www.northeastcoating.com Panacea Powder Coating +1 260 728 4222 www.panaceapowder.com Performance Coatings +1 253 735 1919 www.performancecoatings.com PolyDyn Performance Coatings +1 888 765 9396 www.polydyn.com Praxair surface technologies +1 713 849 9474 www.praxair.com robbjack (Crystallume) +1 866 783 9700 www.robbjack.com ruktech +1 801 783 2325 www.ruktech.com swain tech Coatings +1 585 889 2786 www.swaintech.com tech Line Coatings +1 865 365 1435 www.techlinecoatings.com toefco Powershield Coatings +1 269 683 0188 www.toefco.com uCt Coatings +1 772 872 7110 www.uctcoatings.com us Chrome Corp +1 203 378 9622 www.uschrome.com 42 ï WS2Í TUNGSTEN DISULPHIDE High Performance Dry Lubricant COEFFICIENCY OF FRICTION 0.03 DYNAMIC Ws2 dry lubricant is being successfully used by F1, F3 and World Superbike teams to prevent seizing and galling on Titanium race parts. Applied to military spec DOD-85645 at 0.5microns thick its low coeffiency of friction is used extensively to reduce wear on gears, shafts, threads and suspension parts. For more information please contact us at either: EUROPEAN ENQUIRIES NORTH AMERICAN ENQUIRIES WS2 COATINGS Limited Micro Surface Corporation Unit 17b, HOSM Ind. Estate, Holme on Spalding Moor, York, YO43 4BB Call Dave Clark / Alan Davies on Tel. +44 (0)1430 - 861222 Fax. +44 (0)1430 - 861110 Email: [email protected] Website: www.ws2.co.uk PO Box 788 465 E. Briscoe Drive, Morris, IL 60450, USA Call Ed Fabiszak on Tel. +1-800-248-4221 Email: [email protected] Website: www.microsurfacecorp.com RET_ADTEMP.indd 1 22/06/2012 17:14 P E T M -U E N FR L A O g R CA R .C SI U N I TTE TOR O H E I TO TEC SL ON EW - M N ET E - .R W W W 4 WAYS TO BUY: 1) ONLINE AT WWW.HIGHPOWERMEDIA.COM 2) CALL US ON +44 (0)1934 713 957 DOWNLOAD A SUBS FORM FROM WWW.HIGHPOWERMEDIA.COM AND RETURN BY: 3) FAX TO +44 (0)208 497 2102 4) POST TO ADDRESS BELOW ISSUE 062 ISSU E 061 race engine TECHNOLOGY 063 OLOGY e TECHN MAY 2012 race engin race engin e TECHN ISSUE MARC OLOGY AMARA: an V8 KEN McN the Australi of Master TREVOR KNOWLES : H/AP RIL 2012 d’s Cosw orth Conn at Le Mans • Bearings • Piston • All-el ectric sworth REINV Focus V8 fuell ENTIN on pisto logy ed rec RT RA mph overy position I N WO R LD ND Report • ECUs Holde Supercars • MoroRacing Moto3 • KRE V8 Focus Bonneville Digest • Trevor Knowles at Specialists • ASI Show Automotive R2B2 Pro Mod V8 Engine Digest • n • Fuels Focus EUROPE e18 advanc F SOU to 1000 H EAR T MAY: SU B SC TOd R I B E AY MARCH/A , EURO UK £12.50 PETE Zytek’s PO WE nt • Zytek ’s KERS Engine focus 2012 USA $25, UK £12.50, USA $25, EED O dhound G TH E MAY 2012 JUNE /JULY H E SP ing Bloo n techno Formula Stude Motorsports • Pushrods Focus • KIA & Kinetic KEEPING THI NGS TURNING Powertrain bearings s Focus Focus • Focus • NASCAR EFI Coatings Puma pa NS HU B OF TH E RA CI NG F1 BE YON D T The Co ection l Twin • Puma Paralle IALS LE MANS I6 TURBO SSENT GDI s FACE E Could this still be the INTERadvanced coating future? H ED Focus on LEASA N U 8 THREAT U P Veville salt flats C R A NASC 0 mph at Bonn TO TODAY’S Target 30 R RN EENG INES RO BU DeltaWing’s Le Mans AL N IT IC D A R in challenge rallel tw Bloodhoun 2012 Aston Martin R17 • DeltaWing JUNE /JULY Overseeing IndyCar’s R LD new-generation V6 I N WO turbos TH E COM RT RA M U N ICATIO N S H PO WE U B OF TH E RACI CI NG NG POWE RTRAI TH E RA N WOR LD H U B OF TH E CO IO N S AT IC N MMUN MMU IC AT IO TH E CO PRIL 2012 www.highpowermed ia.com 012 13:26 18/06/2 PE e18 01_062COVER.indd m rmedia.co 1 USA $20, powe www.high 01_06 1COVER.ind d 1 UK £10, EUROPE e15 www.h ighpowe com 13/03/ 2012 race engine TECHNOLOGY special report OFF-TRACK TESTING SECRETS AERO-ELASTICITY IN FORMULA ONE PLUS Clutch tech to win The Grand Prix paddock Suspension state of the art USA $50, UK £20, EUROPE e35 01_F1RT6 COVER 1.indd 1 v6 2012 27/04/2012 11:41 Under the skin of the MWR Toyota CUP RACE ENGINEERING The secrets of the pros RACING THE CAR OF TOMORROW Driver and crew chief insights USA $50, UK £20, EUROPE e35 01 CRTv2.indd 1 v2 2010 23/11/2010 21:19 special report BMW AND APRILIA The Superbike new boys HYDREX HONDA Top privateer team in BSB USA $50, UK £20, EUROPE e35 00_MRT09_Cover2.indd 1 v1 200 9 19/11/09 11:27:54 This report explains all aspects of the performance of top motorcycle machines. We look in depth at the MotoGP machines as well as the Superbike racers used in the World Superbike and AMA Championships. We identify as never before the keys to success in these exciting forms of racing. v5 2011 A 11/07/2011 12:47 NOW EvERY SEPTEMBER special report Inside America’s quickest Funny Car THE CONTINENTAL WAY TECHNICAL FOCUS Chassis and transmission technology uncovered USA $40, UK £20, EUROPE e30 01_DRT2011.indd 1 v2 2011 10/11/2011 14:59 Engineering a Top Fuel car that exploits 8000 bhp for just a few vital seconds is one of the toughest challenges in racing. This report explores in depth the engineering of all forms of professional drag racing, providing a fascinating insight into a surprisingly complex technological endeavour. WORLD RALLY race A EvERY JULY This technical report looks in depth at the cars that compete in the 24 Hour race at Le Mans. Published every July by High Power Media under official licence with the ACO, this report shows you the amazing engineering and technology required to race non-stop twice around the clock. FASTEST OF THE FAST A European approach to Pro Mod WORLD RALLY RACE TECHNOLOGY 2012 MOTORCYCLE RACE TECHNOLOGY 2009 DUCATI – WHAT IS DIFFERENT ABOUT THE DESMOSEDICI? BUY TOdAY Under official licence with the ACO USA $50, UK £20, EUROPE E35 01_24HRT11.indd 1 SPECIAL REPORT SPECIAL REPORT A POWER AROUND THE CLOCK Endurance race engine design secrets race engine TECHNOLOGY race engine TECHNOLOGY MOTORCYCLE race They still use Truck arm suspension, rev counter dials and carburettors but some of the best engineers in all of racing are employed by today’s teams and for them the archaic elements of the car are a great challenge. Blending today and yesterday’s technology provides a fascinating engineering puzzle. THE PROTOTYPE CHASSIS Under the skin of today’s Le Mans cars DRAG RACE TECHNOLOGY 2011 CUP RACE TECHNOLOGY 2010/2011 NASCAR TECH EXCLUSIVE BATTLE OF THE COUPES Audi beats Peugeot at its own game SPECIAL REPORT SPECIAL REPORT special report 24 HOUR race SPECIAL REPORT race engine TECHNOLOGY NOW EvERY FEBRUARY race engine TECHNOLOGY A This report puts the powertrain into the whole car context. Featuring input from many top Formula One technical directors and written by Ian Bamsey, each report is a unique review of the engineering and mechanics of contemporary Grand Prix racing cars, including a preview of future trends. A 24 HOUR RACE TECHNOLOGY 2011 F1 RACE TECHNOLOGY 2012/2013 NEW LOTUS: ENSTONE’S CHARGE BACK TO THE FRONT EvERY APRIL SPECIAL REPORT SPECIAL REPORT A 15:56 RACE ENGINE TECHNOLOGY F1 race F1 race Sign up today to get the knowledge that is power at www.highpowermedia.com rmedia. 03/05/2012 16:06 .indd 1 COVER 01_063 Subscribe to the world’s leading technical magazine on racing engines and receive up to 25% off. PRE-ORdER TOdAY special report SIDEWAYS TO VICTORY Rallying’s extreme engineering NEW RALLY GENERATION Inside the latest World Rally Cars WINNING MONTE CARLO Rally Car development USA $50, UK £20, EUROPE e35 01_WRRTV1_cover.indd 1 v1 2012 28/9/10 13:26:48 Rally cars compete on everyday road tarmac, gravel, dirt, even ice and snow so the World Rally Car has to be very versatile. It’s a 300 bhp missile that accelerates from 0-100 kph in under 3 seconds. The design and development of these cars has never been more deeply analysed. www.highpowermedia.com For further information on High Power Media, Race Engine Technology, RET-Monitor.com or any of the Race Technology Reports please contact: Kaine Ingrouille-Kidd, High Power Media Ltd, Whitfield House, Cheddar Road, Wedmore, Somerset, BS28 4EJ, England. Tel: +44 (0)1934 713957 Fax: +44 (0)208 497 2102 E-mail: [email protected]
© Copyright 2024