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Projekt: Laser-func-light

Laser interference functionalized light metal hybrid ceramic

FKZ 01LY1825A – KMU-innovative – joint project climate protection:
Duration: April 2019 – Oktober 2021

Project partners:
ELB – Eloxalwerk Ludwigsburg Helmut Zerrer GmbH
Fraunhofer-Institute for Material and Beam Technology (IWS)

Network coordinator:
ELB – Eloxalwerk Ludwigsburg Helmut Zerrer GmbH

LFL Forschungsprojekt: ELB/Ceranod

Motivation

The piston group, consisting of pistons, piston rings and cylinder liners, accounts for the largest share of friction losses within a gasoline engine with 48%. By optimizing friction and wear within the piston group – especially on the cylinder running surfaces – a reduction up to 60% in friction losses can be achieved. This results in a CO2 reduction of up to 4%. Expressed in absolute figures, this means a saving of 3.25 million liters of fuel for newly registered cars in Germany and thus a reduction of 8073 tons of CO2.

Goal and Procedure

The goal of the project consists, as a first step, in the development of an innovative wear protection through a composite hybrid layer consisting of a ceramic surface and a polymer wear layer for moving lightweight applications in bearing and engine technology, especially for cylinder surfaces made of Al-Si alloys. As a result, friction and thus fuel consumption can be significantly reduced and wear resistance increased. In the second step, microcavities are introduced using the approach of direct laser interference patterning (DLIP), so that emergency running properties in connection with the polymer inclusions in the hybrid layer are guaranteed.

Innovations and Perspectives

A targeted, surface-modified coating of cylinder running surfaces in Al-Si engine housings means that these are adapted to the increased requirement profile of today’s engine technologies. At the same time, the technologies required to improve this functionality should be designed to be energy-efficient and resource-saving. In particular, high-energy consuming processes are to be avoided and the input material for cylinder running surface processing is to be minimized.

The Federal Ministry of Education and Research (BMBF) is funding this project as part of the “Research for Sustainability" strategy.

Bundesministerium für Bildung und Forschung    Forschung für Nachhaltigkeit