Dana Corporation has announced that it has developed two advanced coating processes for engine bearings and piston rings that greatly improve their durability. Products with these advanced coatings will be on display at the 61st International Motor Show (IAA) in Frankfurt, Germany, through Sept. 25 at Dana’s exhibit.
Chuck Heine, president of Technology Development at Dana, said, "Innovation often happens in the details, as these coating processes demonstrate. These processes and components are invisible to consumers, but the benefits they deliver, such as improved powertrain efficiency and reduced emissions, clearly benefit vehicle manufacturers and buyers alike."
RP100 COATING FOR ENGINE BEARINGS
Dana’s RP100 coating for engine bearings utilizes a thermal spray technology, which uses a flame to uniformly deposit a proprietary coating onto connecting rods and main bearings at a very high speed. RP100 is the first use of this thermal spray coating for an engine bearing application.
Benefits include significantly improved bearing strength and wear resistance. The enhanced bearing performance also makes it possible to use less expensive materials for the crankshaft. The process can also be developed to deposit graduated coatings, shifting from a harder interior to a softer layer on the outer surface.
PCF-480 COATING FOR PISTON RINGS
Dana’s PCF-480 coating for piston rings uses thermal deposition to coat piston rings with a surface that is 30 percent harder than traditional thermally coated rings. The superior coating provides a significant improvement in the wear resistance of the power-cylinder system. The coating fills a groove on the piston ring face to deliver a long-lasting seal. This, in turn, helps to significantly lower emissions by reducing the amount of lubrication oil entering the combustion chamber.
PCF-480 was developed to offset the increased wear caused by the introduction of exhaust gas recirculation (EGR) systems in diesel engines. While EGR helps reduce emissions, it also exposes engine components, such as piston rings, to more corrosive and abrasive conditions. However, the PCF-480 coated rings can achieve wear characteristics similar to those in non-EGR engines.
"Today’s consumers are demanding cleaner running, more efficient diesel vehicles," Heine added. "These coating technologies meet those expectations while also helping to improve durability."