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Sulzer Metco SUMEBore – A Thermal Spray Coating Solution for Remanufacturing of Cylinder Bore Surfaces
2014 APRA European Symposium, May 21-23, 2014, Milano Marittima, Italy
Dr. Peter Ernst, | May 22, 2014
Sulzer Metco
Pumps Equipment Market leader in pump technology and solutions
Metco 2)
Market leader in surface technology and solutions
Chemtech Market leader for separation, mixing and service solutions
Rotating Equipment Services Leading independent service provider for rotating equipment
Overview SULZER Corporation
Main Markets Served Oil & Gas
Power Water
Other industrial markets
2013 Key Figures 1) Sales: CHF 3.26 Billion
ROS: 8.1% ROCE: 12.6%
FT Employees: 15 382
Main Markets Served Transportation
Power Other industrial markets
2013 Key Figures Sales: CHF 708 Million
ROS: 10.1% ROCE: 16.5%
FT Employees: 2 450
1) Without Sulzer Metco 2) Divestiture in 2014
Sulzer Metco Oerlikon Balzers
Sulzer Metco SUMEBore - SULZER METCO Bore Technology
A SUMEBore coated cylinder bore surface offers: Oil consumption reduction
(emission) Lower Fuel Consumption
(emission) Wear resistance (life extension,
emissions) Corrosion resistance (life
extension) The technology is industrialized and
proven in mass production and can be scaled from small to large bores
It is not a one fits all plug and play solution Has to be treated as a complete
system with liner, coating, ring and piston
Sulzer Metco Key Benefits of SUMEBore
15 years of proven performance
Proven for mass production
The only independent solution
More than 3‘500'000 coated cylinder bores on the road, water and air
Capability for remanufacturing of cylinder bores
Highest material flexibility
Corrosion resistance
Friction reduction
Wear reduction
Oil consumption reduction
Weight reduction
Improved bore cooling
Sulzer Metco Engines in production with SUMEBore® Technology
Since Vehicles # Cylinders
Racing
1999 Formula1 (Cosworth / Toyota) 10 / 8
2004 GP2 (Mecachrome) 8
2004 MotoGP (Ducati) 4
2006 World Touring Car Championship (WTCC) / STCC 4/5
2007 LMP1 Le Mans (Peugeot) 8/10/12
2009 Deutsche Tourenwagen Masters (AMG Mercedes) 8
2007 NASCAR (Roush Yates Engines) 8
Sport Cars 2003 / 2015 Bugatti Veyron / Bugatti Veyron Supersport Plus 16
2009 Aston Martin one-77 12
2013 Porsche 918 Spyder 8
Aircraft 2006 Technify (former Thielert Aircraft Engines) 4
Passenger Cars
2000 VW Lupo 1.4l TSI 4
2002 VW Touareg, Phaeton 10
2003 VW Multivan T 5, Passat 5
2013 Audi & Porsche 6 / 8
2013 Audi, Bentley, Volkswagen (A8, Continental, etc.) 12
2013 VW EA 211 (World Engine) 4
2015 Japanese Hybrid Super Car (Cosworth) 6
Trucks 2010 SCANIA 6 / Liners
Marine 2009 Yamaha Motors 6
Leisure 2012 BRP Powertrain Rotax 1 - 4
Equipment Materials
Coating Service
Sulzer Metco Different Engine Applications
Ø 300-1000 mm
Ø 150-300 mm
Commercial Racing
Ø 70-100 mm
Ø 100-150 mm
Ø 70-100 mm
Sulzer Metco SUMEBore coated vehicles
coat
ing
serv
ice
Japanese Hybrid Super
Car (Cosworth)
2015
Sulzer Metco A Surface Coating to Improve the Running Surface
oversized cylinder bore
bore surface preparation / roughening
coating process
final machining / honing
Sulzer Metco
Surface Activation prior to SUMEBore Plasma Coating Application
All currently applied surface activation techniques work well with the SUMEBore® plasma coating process of Sulzer Metco.
The "as sprayed" surface is very smooth on all differently activated surfaces.
500mm
500mm 100mm
200mm
200mm
grit blasting high pressure waterjet
mechanical roughening
200mm
Sulzer Metco Surface activation: alternatives to grit blasting
Walter 60 profile
Mechanical activation tool
Low pressure pulsed waterjet activated surface
Low pressure pulsed waterjet
Sulzer Metco Thermal Spray Process in Detail
Sulzer Metco Plasma Spray Guns
small guns for small bores / block applications with rotating head
larger guns for larger cylinder diameters / liners
Sulzer Metco What we are after in Europe
Sulzer Metco Coating of Liner Blanks (pre-machined only)
Sulzer Metco Flexibility in Material Design
100µ
m
100µ
m
F4397: corrosion resistant steel
100µ
m
F6250: TiO2 (with bondcoat, honed)
F2071: corrosion resistant MMC
XPT512: low alloyed carbon steel
(with bond coat)
Extreme reman option: 1-2mm
Sulzer Metco Finish Machining by Honing
source: Nagel - Maschinen- und Werkzeugfabrik GmbH
Sulzer Metco Unique Surface Topography
parameter value in μmRa 0.15 – 0.35
Rz < 5
Rk < 0.3
Rpk 0.07 – 0.16
Rv k 0.5 – 2.0
Sulzer Metco Smooth surface for reduced friction coefficient
Ra: 0.15 – 0.35 µm Rz: < 5 µm Rk: < 0.3 µm Rpk: 0.07 – 0.16 µm Rvk: 0.5 – 2.0 µm
surface roughness recommendation http://dx.doi.org/10.1016/j.wear.2013.01.026
200µ
m
100µ
m
SEM image of smooth honed surface
Sulzer Metco Materials for SUMEBore Coating Applications
all values in wt-%
C Mn Cr Mo Ni Fe others HV0.3
XPT512 1.0 - 1.3 1.4 - 1.6 1.4 - 1.6 - - balance 450
F4301 1.0 - 1.3 1.4 - 1.6 1.4 - 1.6 - - balance 30% Mo 450
F4334 1.0 - 1.3 1.4 - 1.6 1.4 - 1.6 - - balance 50% Mo 450
F2056 1.0 - 1.3 1.4 - 1.6 1.4 - 1.6 - - balance 35% Al2O3/ZrO2 450
XPT627 0.4 - 0.5 0.4 - 0.8 12.0 - 14.0 2.0 - 3.0 - balance 400
F2071 0.4 - 0.5 0.4 - 0.8 12.0 - 14.0 2.0 - 3.0 - balance 35% Al2O3/ZrO2 400
F4375 - max 0.5 27.5 - 29.5 3.8 - 4.2 max. 0.3 balance 350
F2220 - max 0.5 27.5 - 29.5 3.8 - 4.2 max. 0.3 balance 35% Al2O3/ZrO2 350
F5122 - - 5 - 20 - 75% Cr3C2 800
F2186 600
F6250 - - - - - - TiO2 750
F6399 - - - - - - Cr2O3 850
F6397 - - - - - - FeTiO3 550
composition of F5122 with the addition of 20 wt-% of Mo
Sulzer Metco
Upper cylinder diameter in the cylinder block out of spec
Big end bearings of connecting rods
Cylinder head camshaft bore ID
Air pressure cylinders ID
Water pump body ID
Flywheel housing
Bores in gear covers
Bores in rocker lever housings
Crank shaft gear ID
Camshaft gear ID
…
Further examples of reman with thermal spray
21
Sulzer Metco For more details meet us at booth 33
Sulzer Metco Contacts and Links Dr. Peter Ernst Senior Technical Expert Head of Automotive Venture SUMEBore® Sulzer Metco AG (Switzerland) Rigackerstrasse 16, CH-5610 Wohlen, Switzerland Phone +41 56 618 83 39, Fax +41 56 618 81 99 Mobile +41 79 658 92 05 [email protected] www.sulzer.com Bernd Distler Automotive Venture SUMEBore, The Americas Sulzer Metco (US) Inc. 1101 Prospect Avenue Westbury, NY 11590, USA Phone +1 516 338 2423 Mobile +1 516 413 9691 [email protected] www.sulzer.com
www.sulzer.com/sumebore
Hidetada Mima Key Account Manager Sulzer Metco (Japan) Ltd. 3-4-2 Hikawadai, Tokyo , 179-0084 Japan Mobile +81 90 1880 5658 [email protected] www.sulzer.com Filippo Trotta Sales Manager Sulzer Metco (Europe) c/o Business Center - Ufficio srl via Cassia 1081 00189 Rome, Italy Phone +39 0630260360 Mobile +39 3356202227 [email protected] www.sulzer.com
