辉门活塞环技术

FM活塞环技术交流Johannes.EsserGordonHuang11/05/2010CopyrightFederal-Mogul-Strictlyconfidential,FMownership,allrightsreserved2CustomerConfidentialNov.09.2010ChongqingTechDay市场驱动力与需求法规和市场需求•排放•升功率•升扭矩•耐久•比油耗发动机开发目标•二氧化碳排放•爆发压力•环槽温度•EGR/SCR•颗粒捕集器•燃油喷射策略•机油品质•机油耗•漏气量•摩擦损失对活塞环的要求•低摩擦损失设计•抗拉缸和耐磨性能•防断裂能力•刮油能力•活塞环运动稳定性/漏气量•与活塞和缸套的合理配合•性价比3CustomerConfidentialNov.09.2010ChongqingTechDay汽油机的挑战•为减少摩擦损失，在较小的弹力下的好的机油耗和漏气量水平•提高耐磨性能•更好的抗冷热拉伤性能•替代燃料(酒精)•直喷•各类缸孔表面铸铁/AlSi/无缸套表面处理•升功率不断提高•燃油经济性4CustomerConfidentialNov.09.2010ChongqingTechDay轻型柴油机的挑战•低排放(PM,NOx,CO2)•更高升功率•更高温度•更高爆发压力•PM捕集器/EGR•换油期/机油品质LVD活塞环需求-低摩擦损失-低机油耗-高耐磨性能-良好的抗拉伤性能200970+kW/L200+barEmissionStandardinChina5CustomerConfidentialNov.09.2010ChongqingTechDayMarketTechnical/CommercialRequirementsDriversChallengesRings&LinersAlternativefuelsBiofuelsCorrosionresistanceSyntheticfuelsEthanolEmissionlegislationEGR/SCRWearresistanceCombustionprofileScuffingOilfilmreductionOilscrapingParticulatetrapBlowbyLowFricDesignEnginedurabilityServiceintervallsWearresistanceLifetimeSidefacewearPowerdensityThermalloadMaterialstrengthPeakpressureHeavyDutyEmissionLimitsKeyDemandsParticulatesg/bhp.hr0.10.0501023450.15NOxg/bhp.hrUS’98US’10US’07US’04HeavyDutyDieselEngineChallenges6CustomerConfidentialNov.05.2010SAICTechDay汽油机的能量及损失分布活塞环组摩擦损失Remark:Federal-Mogul’-EstimationforGasolineEngineat2000U/minandloadfactor20-30%UsedPowerenergy30%ExhaustHeatLosses26%Gas-Exchange3%FrictionLosses-upto17%Piston3%Rings4%Bearings4.0%CoolingHeatTransfer24%AuxiliaryValveDrives6%活塞环组引起的摩擦损失约占总摩擦损失的24%活塞环组的摩擦损失占燃油燃烧能量的4%1.CompressionRing1.6%2.CompressionRing0.8%OilRing1.6%7CustomerConfidentialNov.09.2010ChongqingTechDay汽油机摩擦损失的发展264969RelativeConformability153245Ft[N]0,4/1,850,46/2,30,51/2,7Railwidth/-rad.wall[mm]Steel/DLCSteel/NTSteel/CRMaterial/Coating2.02,03,0AxialWidth[mm]3-piece.3-piece.3-piece.RingTypeOilRing5810Ft[N]GGG/DLCGGGGMaterial/Coating1,2x2,91,75x3,32x3,35NapierTaperRingNapierTaperRingNapierTaperRingRingType2ndRing6814Ft[N]Steel/DLCSteel/NTGGG/CRMaterial/Coating1,2x2,91,2x3,11,75x3,55AxialWidthxRadialWall[mm]RRRRRRRingTypeTopRing201020001985GasolineBoreSize85mmTotalFt[N]100130138AxialWidthxRad.Wall[mm]8CustomerConfidentialNov.09.2010ChongqingTechDay汽油机摩擦损失计算FrictionLosss[Watt]1500/min–WOT6000/min–WOT9CustomerConfidentialNov.09.2010ChongqingTechDay自然吸气&增压汽油机弹力概述(量产与开发中项目)•每缸付总切向弹力10CustomerConfidentialNov.09.2010ChongqingTechDay活塞环材料MaterialGreycastironGOE13CarbidiccastironF14SpheroidalcastironKV4Cr-steelNitridedFaceCoating•Plain•Chrome•fullfaceorsemi-inlaid•Plain•Chrome•fullfaceorsemi-inlaid•Nitrided•Plain•Chrome•fullfaceorsemi-inlaid•--•--•nonnitrided•NitridedGroove2,321onLVD1,3SegmentGasoline/LVDieselall2,3Gas+DieselGasolineTOPGas+Diesel3rd11CustomerConfidentialNov.09.2010ChongqingTechDay活塞环外圆镀层汽油机+柴油机Max.50µmCrN(LVP)CrON(LVD)DLC(LVP)PVD1000-2100HV0.0518%Cr-Steel(Side-Nt)C-Steel(noside)NitridingNitride700-1200HV0.0513%-18%Cr-Steel0.5-5µmAl2O30.1-0.5µmDiamondGDC®CKS®CompositeChrome900-1200HV0.1-TopCompression-OilRingDuctileCastIron(Side-Blitz)18%Cr-Steel(Side-Blitz)C-Steel(Side-Blitz)HVOFMKJet®1000-2100HV0.05DuctileCastIron(Side-Blitz)18%Cr-Steel(Side-Nt+Blitz)C-Steel(Side-Blitz))-TopCompression-OilRing-TopCompression-1stCompr.Gasoline-OilRingCOATINGMATERIALTOPRINGDESIGN12CustomerConfidentialNov.09.2010ChongqingTechDay外圆镀层CKS/GDC®沉积原理CracknetworkwithsubstructureCrackwidthLayerthickness=crackdepthF-MistheinventoroftheoriginalCKSandGDC®–陶瓷颗粒(Al2O3,2-5µm)CKS–钻石颗粒(0,25-0,5µm)GDC复合电镀技术在欧洲已广泛应用LVDiesel(80%shareinEurope)TurboGDITruckApplicationsEU5(70%shareinEurope)LowwearThickcoatingsSharpbottomedge13CustomerConfidentialNov.09.2010ChongqingTechDayPVD240-CrONCoatingCharacteristic:•Structure:CrNpredominant[200]oriented•Hardness:1500–2200HV0.1•Thickness:30/50µmTechnologicalProperties:•goodwearresistance•goodscuffresistance•lowfrictioncoefficientcomp.tosteelApplicationinHD–Dieselengine:•TopringSteelnitridedPVD242–CrNCoatingCharacteristic:•Structure:CrNpredominant[200]oriented•Hardness:800–1400HV0.1•Thickness:10/30µmTechnologicalProperties:•goodwearresistance•goodscuffresistance•lowfrictioncoefficientcomp.tosteelApplicationDieselandGasoline:•TOP-RingSGIandSAE-steel•2.RingonSGI•oilringsonSGIandsteelPVD243-CrONCoatingCharacteristic:•Structure:CrNpredominant[200]oriented•Hardness:1400–2200HV0.1•Thickness:10/30µmTechnologicalProperties:•goodwearresistance•goodscuffresistance•lowfrictioncoefficientcomp.tosteelApplication:Gasoline•TopringChromesteel-nitrided•3-pc.OilringnitridedPVD-镀层14CustomerConfidentialNov.09.2010ChongqingTechDayPVD-应用于汽油机和柴油机高抗拉缸能力和低摩擦损失WearratePVD243InTurbo-GDI5µm/1000h(exemple.)15CustomerConfidentialNov.09.2010ChongqingTechDayNitrideLayerDLCincreasedriskofnocylinderdamagescylinderscuffingbestrunning-inhighscuffresistancelowestfrictiononAlandcastironsuperiourDLCringsurfaceonrunningfaceDLC应用于铝机体的活塞环镀层withoutDLCDLCDLCnitridednitridedDLCVisualinspectionofcylinderboresafterenginetestVisuellinspectionofringsaftercoldstarttest16CustomerConfidentialNov.09.2010ChongqingTechDayHP-DLC镀层应用于汽油机a-