aluminum cylinder block
TRANSCRIPT
Replacing the Cast Iron Liners for Aluminum Engine
Cylinder Blocks: A Comparative Assessment of Potential
Candidates
by
John Lenny Jr.
An Engineering Project Submitted to the Graduate
Faculty of Rensselaer Polytechnic Institute
in Partial Fulfillment of the
Requirements for the degree of
MASTER OF ENGINEERING IN MECHANICAL ENGINEERING
Approved:
_________________________________________
Professor Sudha Bose, Project Adviser
Rensselaer Polytechnic Institute
Hartford, Connecticut
April 2011
ii
© Copyright 2011
by
John Lenny
All Rights Reserved
iii
CONTENTS
CONTENTS ..................................................................................................................... iii
LIST OF TABLES ............................................................................................................ vi
LIST OF FIGURES ......................................................................................................... vii
ACKNOWLEDGMENT ................................................................................................ viii
ABSTRACT ..................................................................................................................... ix
1. Introduction .................................................................................................................. 1
1.1 Modern Passenger Car Fuel Economy .............................................................. 1
1.2 Increased Government Regulations ................................................................... 2
1.3 Automakers Ability to Meet New Regulations .................................................... 2
1.3.1 Objective of this Project ......................................................................... 2
1.4 Limitations of Current Cylinder Block Design .................................................. 3
1.4.1 Cylinder Block Requirements ................................................................. 4
1.5 Alternative Cylinder Block Solutions ................................................................. 7
2. Background .................................................................................................................. 8
2.1 The Cylinder Block ............................................................................................. 8
2.1.1 Cylinder Block Manufacturing ............................................................... 9
3. Methodology .............................................................................................................. 10
3.1 Hypereutectic Aluminum Silicon Alloy Cylinder Blocks .................................. 11
3.1.1 System Description ............................................................................... 11
3.1.2 Past Research and Development .......................................................... 14
3.1.3 Benefits of Hypereutectic Al-Si Alloys ................................................. 16
3.1.4 Drawbacks of Hypereutectic Al-Si Alloys ............................................ 16
3.1.5 Conclusions .......................................................................................... 17
3.2 Fiber or Particle Reinforced Aluminum Alloys for Cylinder Blocks ............... 18
3.2.1 Background Information – Defining a Composite ............................... 18
iv
3.2.2 Component Description ....................................................................... 19
3.2.3 Past Research and Development .......................................................... 20
3.2.4 Benefits of Fiber or Particle Reinforced Al Alloys .............................. 23
3.2.5 Drawbacks of Fiber or Particle Reinforced Al Alloys ......................... 25
3.2.6 Conclusions .......................................................................................... 26
3.3 Thermal Spray Coating of Aluminum Cylinder Block Walls ........................... 27
3.3.1 Process Description ............................................................................. 27
3.3.2 Past Research and Development .......................................................... 29
3.3.3 Benefits of Thermal Spray Coating ...................................................... 31
3.3.4 Drawbacks of Thermal Spray Coating ................................................. 32
3.3.5 Conclusions .......................................................................................... 33
3.4 Electroplating Aluminum Cylinder Block Bore Surface .................................. 34
3.4.1 Process Description ............................................................................. 34
3.4.2 Past Research and Development .......................................................... 36
3.4.3 Benefits of Electrolytic Coating Process.............................................. 38
3.4.4 Drawbacks of Electrolytic Coating Process ........................................ 39
3.4.5 Conclusions .......................................................................................... 40
4. Comparative Analysis ................................................................................................ 41
4.1 Comparison Categories ................................................................................... 41
4.1.1 Previous Applications .......................................................................... 41
4.1.2 Wear Resistance ................................................................................... 42
4.1.3 Scuffing Resistance............................................................................... 42
4.1.4 Thermal Conductivity ........................................................................... 43
4.1.5 Friction between cylinder block and piston rings ................................ 43
4.1.6 Fuel Economy....................................................................................... 44
4.1.7 Engine Emissions ................................................................................. 45
4.1.8 Manufacturing Costs ............................................................................ 45
v
4.1.9 Engine Performance............................................................................. 46
4.1.10 Mass Production Feasibility ................................................................ 46
5. Summary .................................................................................................................... 47
5.1 Results of Comparison ..................................................................................... 47
5.2 Future of Alternatives ...................................................................................... 49
6. References .................................................................................................................. 54
vi
LIST OF TABLES
Table 1: Alternatives for Replacing Cast Iron Cylinder Bore Liners ................................ 7
Table 2: Development of Hypereutectic Al-Si for Automotive Engine Blocks .............. 14
Table 3: Comparison of various types of bore designs [28] ............................................ 24
Table 4: Comparison of Thermal Spray Processes for Aluminum Cylinder Bores [43] . 28
Table 5: Results of Comparison ...................................................................................... 47
Table 6: Results of Comparison based on Future MPG Requirements ........................... 50
Table 7: Applications of the Candidate Alternatives for Cast Iron Liners ...................... 51
vii
LIST OF FIGURES
Figure 1: Inflation Adjusted Average Annual Gasoline Prices 1918-2009 [1] ................. 1
Figure 2: Sulfur Concentration in unleaded fuel [28] ........................................................ 5
Figure 3: Breakdown of friction loss for engine components [34] .................................... 5
Figure 4: General Motors Inline Four Cylinder Block [55] .............................................. 8
Figure 5: Aluminum-Silicon phase diagram [45] ............................................................ 11
Figure 6: Principle of Operation for Hypereutectic Al-Si Alloy Cylinder Block [42] .... 13
Figure 7: Hypereutectic Al-Si Cylinder Block Surface Exposure Step [42] ................... 13
Figure 8: Different Fiber Orientations in a Composite [49] ............................................ 18
Figure 9: Aluminum-matrix MMC filled with Al2O3 agglomerates [45] ........................ 19
Figure 10: Cast Aluminum/Graphite Metal Matrix Composite Cylinder Liner [23] ...... 21
Figure 11: 2ZZ-GE MMC Cylinder Block [28] .............................................................. 22
Figure 12: Scheme of Thermal Spray Coating Process [46] ........................................... 27
Figure 13: Ford Sigma PTWA Apparatus ....................................................................... 30
Figure 14: Nickel Silicon Carbide composite applied to a cylinder bore [36] ................ 34
Figure 15: Plasma Electrolytic Oxidation Process [48] ................................................... 35
Figure 16: SEM micrograph of a typical PEO coating on aluminum [53] ...................... 36
Figure 17: Comparison of surface frictional coefficients for NCCs and Cr [34] ............ 38
Figure 18: Relationship of Emissions and Fuel Economy as MPG Requirement Increases
.......................................................................................... Error! Bookmark not defined.
viii
ACKNOWLEDGMENT
I would like to thank my family for their support over the years while I pursued
my degree. I would also like to thank Professor Bose for his guidance and support
throughout the process.
ix
ABSTRACT
The United States federal government has mandated that all automobile
manufacturers increase their vehicle fleet miles per gallon average to 35.5 by 2016. This
will challenge automakers to find ways to decrease vehicle weight and frictional loss
between powertrain components. One approach to increasing an automobile’s fuel
economy by reducing vehicle weight and friction loss simultaneously is to remove the
cast iron cylinder block liners and replace them with a lighter more thermally efficient
material. However, cast iron liners are needed on aluminum cylinder blocks because
they possess the necessary tribological characteristics. The focus of this paper is to
research possible alternatives to using cast iron liners for aluminum cylinder blocks. The
information gathered will be used to perform a qualitative comparison among the
alternative methods to assess their validity.
1. Introduction
1.1 Modern Passenger Car Fuel Economy
Recently in the United States a major shift has occurred in the public’s
perception of the importance of automobile fuel efficiency. The production of oversized
four ton gas guzzling sport utility vehicles has ended and has been replaced with smaller
more efficient passenger cars are being produced in greater numbers. There are several
factors that attributed to the focus of automobile fuel efficiency in this country. The first
is our susceptibility to oil market manipulation and the price shock. As a result of this
gas prices rose steadily from 1998 to 2008 with the national average for a gallon of gas
reaching $4.00 in July of 2008, Figure 1.
Figure 1: Inflation Adjusted Average Annual Gasoline Prices 1918-2009 [1]
Gases prices dipped from their historic highs in 2008 but have been creeping up again in
later stages of 2010 and into 2011.
Another reason for increased fuel consumption awareness is the growing concern
of pollution generated by automobile emissions. Research showed that the carbon
dioxide (CO2) produced from burning gasoline and diesel fuel in automotive engines is
contributing to global climate change [2].
2
Coupling of those first two factors with the struggling US economy at the end of
decade the moved the notion of conserving fuel and reducing emissions to the forefront
for government intervention. As a result, in 2009 the government stepped in to provide
the necessary legal enforcement of the decrease in emissions and increase in average fuel
economy for passenger cars.
1.2 Increased Government Regulations
On May 19, 2009 President Barack Obama proposed a new national fuel economy
program which adopts uniform federal standards to regulate both fuel economy and
greenhouse gas emissions while preserving the legal authorities of DOT, EPA and
California [3]. The program covers 2012 model year cars to 2016 model year cars and
ultimately requires an average fuel economy standard of 35.5 miles per gallon (mpg) by
2016 a increase from the current 25 mpg average for all vehicles.
President Obama said the program would save 1.8 billion barrels of oil “over the
lifetime of the vehicles sold in the next five years”. The increased miles per gallon
should cut greenhouse emissions by more than 900 million tons, the equivalent to
shutting down 194 coal plants.
1.3 Automakers Ability to Meet New Regulations
This new legislation for increasing the minimum mpg average for an automaker’s
fleet changes the design requirements for the automobiles sold in the United States. The
two major approaches for increasing automobile fuel economy is to improve powertrain
efficiency and to reduce the rolling resistance. The best approach for improving
powertrain efficiency is to reduce friction loss and the best approach for reducing the
rolling resistance is to reduce vehicle weight.
1.3.1 Objective of this Project
One of the ways to aid in an automobile’s fuel economy by reducing vehicle
weight and reducing friction loss simultaneously is to remove the cast iron cylinder
block liners and replace them with a lighter, more thermally efficient material. The
objective of this paper is to research and compare the different alternatives for replacing
3
the cast iron liners that are typically used in today’s modern passenger cars in
conjunction with an aluminum engine block. The information collected from the
research will then be used to perform a qualitative comparative analysis to find out
which alternative is the best replacement candidate.
Changes in the design for mass production are not taken lightly because of the
associated cost. Replacing the iron liners used in conjunction with aluminum cylinder
blocks is no exception. That is to say until recently when the government required that
all automobile fleets to increase the average fuel economy, the idea of replacing the iron
liners previously identified as too expensive, could become a necessity.
1.4 Limitations of Current Cylinder Block Design
In the past automakers have moved from cast iron to aluminum cylinder blocks
for weight shedding purposes. Replacing cast iron with aluminum for engine cylinder
blocks has the potential for a sizable reduction in block weight, up to 45% for gasoline
engines [5]. The downside to using aluminum as the cylinder block material is that the
traditional aluminum alloys do not have the required tribological characteristics for
required for engine block material. Therefore switching to aluminum for cylinder blocks
has created the need for surface engineering technologies capable of overcoming these
tribological characteristic deficiencies. Historically, the solution was to sleeve the
cylinder bores with cast iron to meet the required surface characteristics. Cast iron liners
are low-cost, durable, and easy to manufacture, which are the key criteria for mass
produced automobiles. That solution was perfectly fine until the federal government
mandated that automakers raise their fleet mpg average. Now the automakers are
searching into new ways or resurrecting old solutions to increasing automobile fuel
economy.
Moving away from cast iron sleeves gives the automakers an opportunity to
solve some of the secondary issues with using cast iron sleeves on aluminum cylinder
block bores. While cast iron liners are a cost effective solution at the moment, they have
the inherent disadvantages in weight, size, thermal conductivity, differential thermal
expansion and recyclability compared to the potential alternative materials. The
different thermal expansion coefficients of gray cast iron and the aluminum cylinder
4
block material can cause deformation of the liner and also local heat transfer problems if
the liner disengages from the engine block [32]. Particularly the deformation of the liner
leads to an increased oil and fuel consumption and increasing emissions. The liner-
equipped engine is still unnecessarily large, still has differential expansion and reduced
heat dissipation issues, still needs a heavier and larger cooling system, etc.
1.4.1 Cylinder Block Requirements
Internal combustion engine cylinder blocks must satisfy a number of functional
requirements. Within the cylinder, the combustion process produces rapid and periodic
rises in temperature and pressure, shear loading, and impingement of hot gases. The
extreme pressure from the combustion process induces circumferential and longitudinal
tensile stresses. The functional requirements include lasting the entire life of the vehicle,
housing internal moving parts and fluids, ease of service and maintenance of internal
components, and withstand pressures created by the combustion process. Cylinder block
bore surface material must have high wear resistance and capable of withstanding high
pressures on the order of 100 to 200 bar [7] in engines with high peak firing pressures.
The porosity level of the material must be below 1% and the maximum pore size must
be below 500 microns [7] on the running surfaces.
In order for cylinder block to meet these functional requirements the engineering
materials used to manufacture the product must possess high strength, modulus of
elasticity, wear resistance, scuffing resistance, and corrosion resistance. The material of
the cylinder block must be of a sufficient hardness to resist the wearing of the piston as it
slides up and down on the cylinder wall.
Two of the most important material characteristics that are needed for the
cylinder block surface are wear and scuffing resistance. Wear is erosion or displacement
of material from its original position on a solid surface performed by the action of
another surface [57]. Scuffing is the phenomenon characterized by mass movement of
surface elements to form linear scratches and local welds on surfaces in relative motion
[56]. Wear and scuffing occurs on the cylinder bore surface when the lubrication
conditions deteriorate. It is known that wear on the cylinder bore surface is promoted
when acid adheres to the bore surface during engine warm up as a result of sulfur in the
5
fuel [53]. Figure 2 below is a graph showing the sulfur concentration in gasoline in
various parts of the world. Toyota used this information to help guide their cylinder
block material selection for use in a sports car application in the late 1990s.
Figure 2: Sulfur Concentration in unleaded fuel [28]
Another important requirement for cylinder block material is its coefficient of
friction. Friction between the cylinder block surface and the piston rings has a major
impact on the efficiency of an automobile’s powertrain. Friction accounts for a loss of
over 40% of the total vehicle power [43]. Over half of that power loss can be attributed
to the frictional loss between piston rings and cylinder bores as shown in Figure 3 below.
Therefore in order for the alternative to be a viable option for replacing cast iron liners
the more it can reduce the frictional loss between the cylinder liner and the piston ring
Figure 3: Breakdown of friction loss for engine components [34]
6
The aluminum alloys used for cylinder blocks demand strictly controlled
characteristics and mechanical properties to meet the functional requirements mentioned
above in order to perform as expected in modern automobiles. In summary the key
characteristics that a cylinder block material must possess are as follows:
Cylinder Block Material Characteristics
High strength Low density
High Modulus of Elasticity Low thermal expansion
High wear resistance Good machinability
High scuffing resistance Good castability
High corrosion resistance Good vibration dampening
High thermal conductivity
7
1.5 Alternative Cylinder Block Solutions
The four most promising alternative approaches for improving the tribological
characteristics of aluminum cylinder bores include hypereutectic aluminum silicon alloy
cylinder blocks, fiber or particle reinforced aluminum matrix composite cylinder blocks
or liners, thermal spray coatings on the cylinder bore, or electrochemical deposited
coatings on the cylinder bore. Each one of these four alternative approaches is discussed
in detail in this project. The first two alternatives are different material types altogether
compared to the traditional hypoeutectic aluminum alloys used for cylinder blocks. The
second two alternatives propose to maintain the use of hypoeutectic aluminum alloys but
to coat the bore surface with a hard wear resistant material that will meet the design
requirements. Table 1 below contains a description of each alternative with the key
characteristics of each in bold.
Table 1: Alternatives for Replacing Cast Iron Cylinder Bore Liners
Current Design
1. Hypoeutectic aluminum alloy cylinder block with cast iron cylinder bore liners
Alternative Designs
1. Hypereutectic aluminum silicon alloy cylinder block
2. Fiber or particle reinforced aluminum matrix composite cylinder block or
cylinder bore liner only with hypoeutectic aluminum silicon alloy cylinder block
3. Hypoeutectic aluminum silicon alloy cylinder block with cylinder bores coated
with a material deposited with a thermal spray process
4. Hypoeutectic aluminum silicon alloy with cylinder bores coated with a material
deposited with electroplating process
8
2. Background
2.1 The Cylinder Block
The cylinder block is the portion of the engine between the cylinder head and the
oil pan and is the supporting structure for the entire engine. All the engine parts are
mounted on it or in it and holds the parts in alignment. Large diameter holes in the
block-castings form the cylinder bores required to guide the piston. The surface of these
bores is commonly referred to as the cylinder walls. The cylinders are provided with a
web or bulkhead to support the crankshaft and head attachments. The bulkhead is well
ribbed to support the applied loads giving the block structural rigidity and beam
stiffness. The cylinder block has separate passages for the flow of coolant and
lubricating oil.
Figure 4: General Motors Inline Four Cylinder Block [55]
The cylinder block is a complex part to cast because of the crankshaft/head bulkheads,
bulkhead support ribs and the cooling passages. There are several different
configurations for cylinder blocks. The two most widely used configurations are inline
and v-banked cylinder blocks. A third configuration called horizontal opposed cylinder
block is used more sparingly for production cars.
9
2.1.1 Cylinder Block Manufacturing
Most of the automotive cylinder engine blocks made out of aluminum alloys are
currently manufactured by casting the block body in silica sand molds using sand cores
and inserting a set of cast iron liner to form the cylinder-piston contact surfaces. [7].
Other processes for casting blocks have included gravity feed semi-permanent molds,
high pressure die casting, low pressure die casting, the lost foam process and the zircon
sand package molds [7]. The cast iron liners can be inserted into the aluminum cylinder
block by a “cast-in” or “pressed-in” process. Cast iron liners have been placed like cores
in the casting mold for inclusion in the blocks or inserted in the machined cylinder bores
[25].
Typically when current cylinder blocks are cast of aluminum alloy they are either
made with 319 or A356 where A356 with a T6 heat treatment is gaining more
widespread usage for the US automakers. The T6 process is a solution heat treatment
and aging treatment used to increase the tensile and yield strength of the aluminum alloy.
A356 alloy meets or exceeds all the requirements for the mechanical strength, ductility,
hardness, fatigue strength, pressure tightness, fluidity, and machinability. Both alloys
require either cylinder liners or surface treatment to the cylinder walls to provide
sufficient wear resistance during operation. Aluminum alloys that can be suitably cast
and machined to make cylinder blocks have lacked cylinder wall wear resistance in
service. Engine manufacturers in the past have selected castable and machineable
aluminum alloys and then modified the cylinder wall surface to obtain the necessary
wear resistance [25].
10
3. Methodology
This project will cover the four main alternatives for replacing cast iron liners for
aluminum cylinder blocks. Each alternative will be characterized with a complete
system description, summary of past development, applications, and the positives and
negatives of that given approach. Information on each alternative will be gathered using
online engineering databases and articles from relevant technical publications. This
information will serve as the basis for making a comparative analysis between the
alternatives.
11
3.1 Hypereutectic Aluminum Silicon Alloy Cylinder Blocks
One of the earliest approaches to eliminating the need for lining the cylinder block
bore surface was to cast the block out of a hypereutectic aluminum silicon alloy rather
than a traditional hypoeutectic aluminum silicon alloy.
3.1.1 System Description
A hypereutectic aluminum-silicon (Al-Si) alloy differs from previously used
hypoeutectic Al-Si alloys in that it has a higher concentration of silicon. A hypereutectic
Al-Si alloy is over saturated with silicon. During the formation of the alloy silicon
particles dissolve in the molten aluminum and become inseparable. However, above the
saturation point, known as the eutectic point, silicon will not dissolve but rather
precipitate out in crystal form. Typically, this saturation point in aluminum occurs
approximately at a 12% silicon concentration, shown in Figure 5 below. Commercial
grade hypereutectic Al-Si alloys range from 12% to 20% or more in silicon
concentration. Beyond 20% silicon concentration the alloys hardness reaches a level
where it can no longer be machined using traditional machinery. Therefore in terms of
minimizing casting costs for producing cylinder blocks it is important that the material
be machinable using standard tooling.
Figure 5: Aluminum-Silicon phase diagram [45]
The additional silicon concentration gives the hypereutectic Al-Si alloy adequate
hardness for use as a cylinder block material. Silicon is the second hardest element
12
behind diamond. The primary silicon particles of a hypereutectic Al-Si alloy that
crystallize out of the mold while the casting cools, is what increases the materials wear
resistance to an acceptable level for a cylinder block surface application. In addition to
the silicon content, small amounts of other elements are likely to be included such as
copper, manganese, magnesium, phosphorus, nickel, titanium, and strontium. These
additional elements improve the casting properties of the hypereutectic Al-Si alloy. For
instance, adding copper increases the fluidity of the molten aluminum during the pouring
process which improves the quality of the casting. Adding magnesium increases the
strength of the alloy at elevated temperature without increasing ductility. When a
hypereutectic Al-Si alloy is chosen as the cylinder block material, the optimum micro
structure for the casting is to have uniformly distributed primary silicon crystals in an
eutectic Al-Si matrix. The uniformly distributed primary silicon particles are the key
material characteristic for the cylinder block surface. If there is a large section of the
casting without silicon particles, that area will quickly be worn away by the piston rings
and could cause premature engine failure.
The operating environment of the internal combustion engine’s cylinder block is
very demanding. The speed at which the piston and piston rings reciprocate on the
cylinder block bore surface requires the material to be extremely hard and wear resistant.
The principle of operation for a hypereutectic Al-Si alloy as the cylinder block material
is shown below in Figure 6. The piston ring rides on a combination of lubricant and the
primary silicon particles in the aluminum.
13
Figure 6: Principle of Operation for Hypereutectic Al-Si Alloy Cylinder Block [42]
To ensure the piston rings slide on the hard primary silicon particles of the alloy
and not the parent aluminum material, a chemical etching is applied to the cast piece to
create a surface where individual silicon particles protruded a small distance above the
parent aluminum material [42]. This process in cylinder preparation is called the
exposure step shown below in Figure 7. The silicon particles form the supporting
structure for the pistons and piston rings.
Figure 7: Hypereutectic Al-Si Cylinder Block Surface Exposure Step [42]
14
After the exposure step is accomplished, the manufacturing process for the hypereutectic
Al-Si alloy cylinder block is similar to the process followed with a hypoeutectic Al-Si
with cast iron liners.
3.1.2 Past Research and Development
An early application of hypereutectic Al-Si alloy as a cylinder block material was
Porsche engines in 1960’s. The first application of hypereutectic Al-Si alloy for the US
market came in 1971 when General Motors (GM) used Reynolds A390 aluminum alloy
for the cylinder block in the Chevy Vega. GM did not have great success with the A390
aluminum because of the difficulty of casting the alloy with a uniform dispersement of
primary silicon particles. Since then there has been several key advancements in the
design of hypereutectic aluminum-silicon alloys for cylinder blocks captured below in
Table 2.
Table 2: Development of Hypereutectic Al-Si for Automotive Engine Blocks
Document Description/Impact
US Patent 3,895,941
July 22, 1975
G. F. Bolling, et. al.
Teaches a method of preparing an improved hypereutectic al-si alloy
One mode comprises the addition of sintered aluminum powdered rods
containing Al2O3 particles, uniformly distributed throughout, to a
hypereutectic melt of aluminum [21]
US Patent 4,434,014
February 28, 1984
David M. Smith, et. al.
Teaches properties of a castable hypereutectic aluminum alloy
Teaches Mi, Fe, and Mn are interchangeable with each other
Titanium is added to improve castability
High cost due to high content of Nickel
US Patent 5,217,546
June 8, 1993
John A. Eady, et al.
Development of a hypereutectic Al-Si alloy that has primary Si
particles uniformly dispersed and free of segregation
The alloy however relies on titanium and a large amount of nickel
which makes it an expensive alloy for mass production purposes
US Patent 5,316,070
May 31, 1994
Kevin P. Rodgers, et.
al.
Teaches a process for controlled casting of a hypereutectic Al-Si
Controlled cooling of the mold in critical areas, to remove/prevent
excessive accumulation of heat energy and avoid the formation of
intense convection currents
The growth of the Al-Si eutectic is promoted and the resultant
microstructure is substantially free of primary Si.
WO 2008/053363
Salvador Valtierra-
Gallardo, et. al.
Discloses an Al-Si alloy composition that meets the manufacturing and
performance conditions for liner-less cylinder engine block casting
using low-cost casting processes such as silica-sand molds
Uses the addition of sintered aluminum powdered rods containing
aluminum oxide particles, uniformly distributed throughout to a
hypereutectic melt of aluminum-silicon
15
3.1.2.1 Current R&D and Applications
In today’s automobile market manufacturers using hypereutectic Al-Si alloys
include Mercedes, Audi, Porsche, BMW, Volvo, VW, Jaguar, and Honda. Alusil®,
Lokasil®, Silitec ®, DiASil, Mercosil, ALBOND®, are all trade names or trademarks
for hypereutectic Al-Si for cylinder bore wear surfaces. In each case the engines using
the hypereutectic material are typically low volume, larger engines with six or more
cylinders. One of the leading manufacturers of hypereutectic Al-Si cylinder blocks is
KS Aluminum-Technologie AG (KS ATAG), a Kolbenschmidt Pierburg AG company.
KS ATAG has been producing hypereutectic Al-Si alloys for the last ten years. The
successful formulations are low-pressure die cast cylinder blocks made from
hypereutectic alloy AlSi17Cu4Mg and Alusil® [24].
Alusil® is a hypereutectic Al-Si alloy. KS ATAG produces cylinder blocks out
of Alusil® with a low-pressure die cast process. The cylinder block’s primary silicon
particles are formed during solidification as small, hard grains, on the surface of the
cylinder bores [24]. The silicon surface is porous enough to hold oil, and is an excellent
bearing surface. Alusil® is used in the majority passenger automobiles with larger, eight
cylinders or more, engines in Europe. Currently Audi, Volkswagen, BMW and Porsche
all use Alusil® for one or more of their production car cylinder blocks. Development of
hypereutectic Al-Si for the US market could come from KS ATAG importing their
technology or selling the rights to use their proprietary materials.
Another manufacturer with recent success with a hypereutectic Al-Si alloy
cylinder block is Mercury Marine. Mercury Marine created a castable copper-free
hypereutectic Al-Si alloy, Mercosil, for internal combustion engine cylinder blocks.
Along with primary silicon particles dispersed in the parent aluminum matrix, Mercosil
has particles of a solid lubricant embedded in the cylinder wall to further enhance the
wear resistance of the material. Through testing Mercury Marine has shown that the
copper-free hypereutectic Al-Si alloy Mercosil is superior to A390 hypereutectic
aluminum alloy in that Mercosil yields a more uniform distribution of primary silicon
and makes sound castings easier to produce, particularly in a slow cooling rate process
such as lost foam [20].
16
3.1.3 Benefits of Hypereutectic Al-Si Alloys
The validity of replacing cast iron lined aluminum cylinder blocks with an all
aluminum cylinder block made from a hypereutectic Al-Si alloy is dependent upon the
benefits it provides. Hypereutectic Al-Si alloys have the necessary wear resistance for
the cylinder block bore surface with a thermal conductivity of nearly 400% higher than
that of cast iron [20]. This benefits the operational efficiency of the engine because it
allows the heat to transfer more evenly thru the aluminum making the block easier to
keep cool, reducing the cooling load and therefore reducing the engine cooling system.
Uniformly transferring the heat from the combustion process enables the manufacturers
to design for higher operating temperatures which increases engine power and reduces
emissions.
Hypereutectic Al-Si alloys have high cycle fatigue strength 50% higher than that
of hypoeutectic Al-Si alloys [20]. Hypereutectic Al alloys do not require heat treatment,
which may eliminate internal stresses that may cause fatigue failure [7]. The low
coefficient of thermal expansion, high hardness and good wear resistance of
hypereutectic aluminum silicon alloy makes it an excellent choice for a lightweight
cylinder block material.
Hypereutectic Al-Si alloys also provide several benefits over cast iron block or
aluminum blocks with cast in liners in terms of manufacturing processes. Improving the
casting yield and producing a near net shape using hypereutectic Al-Si increases its cost
competitiveness over a long period of time compared to the traditional material
combinations. Hypereutectic Al-Si alloys enable foundries to use die casting instead of
sand casting which reducing machining costs and produces better material properties.
The all aluminum engines blocks are also highly recyclable, which cheapens the raw
material and energy consumption.
3.1.4 Drawbacks of Hypereutectic Al-Si Alloys
There are certain material characteristics that are preventing hypereutectic Al-Si
alloys from wholly replacing cast iron liners. Principally the reason being that
hypereutectic Al-Si alloys are extremely difficult to cast with the proper material
characteristics for cylinder blocks. General Motors was one of the first automakers to
17
find this out in the 1970’s, the Reynolds A390 hypereutectic aluminum cylinder blocks
they used for the Chevy Vega proved difficult to repeat the physical characteristics for a
mass production run of engine block castings. The tribological characteristics of
hypereutectic Al-Si alloys are determined by the distribution of silicon particles in the
as-cast condition. During the casting process it is difficult to control the distribution of
the silicon particles.
Cost also plays a role in preventing hypereutectic Al-Si alloys from being used in
modern passenger cars. Traditionally hypereutectic aluminums have expensive alloying
elements such as magnesium and nickel. Additionally hypereutectic Al-Si alloys require
a chemical etching step after the material is casted to expose the primary silicon particles
so that the piston and piston rings slide on only the silicon particles.
3.1.5 Conclusions
Hypereutectic Al-Si alloys for cylinder blocks has become an increasingly
attractive alternative for solving the tribological deficiency of most commercialized
aluminum alloys mainly as a result of improving the casting processes. Right now the
European car market has proven that hypereutectic Al-Si alloys become a viable
alternative for premiere luxury vehicles that have larger engines. Once the alloy is
commercialized in the US it will drop the price of the raw material and increase the
attractiveness of hypereutectic Al-Si alloy cylinder blocks.
18
3.2 Fiber or Particle Reinforced Aluminum Alloys for Cylinder Blocks
A second option for replacing aluminum cylinder blocks with cast iron liners is
to use a metal matrix composite (MMC). The composite material can be used for either
the entire block or as a MMC liner in conjunction with a common aluminum alloy. The
metal matrix composite cylinder blocks and liners are often referred to as fiber or
particle reinforced cylinder blocks in the automotive industry. Fiber or particle
reinforced is a description of the physical composition of the composite reinforcements.
3.2.1 Background Information – Defining a Composite
A composite is a material in which two or more distinct, structurally
complementary substances combine to provide structural or functional properties not
present in the individual component. The constituents are formed together by physical
means and not by chemical bonding of alloys. A composite is made up of a matrix, and
one or more reinforcements. The matrix provides the overall structure of the composite;
it surrounds the fibers. In the fiber reinforced composites, the fibers are individual
filaments of material embedded in the matrix that increase the composite’s strength and
other sought after properties beyond that of the individual matrix material. The fibers
can take the form of whiskers, which are single crystals of material, continuous fibers,
which are essentially infinite in length, or discontinuous fibers, which are short in length
but generally more than 3mm long [45]. The fibers can also have several difference
orientations within the matrix, as shown below in Figure 8.
Figure 8: Different Fiber Orientations in a Composite [49]
19
The reinforcement fibers aren’t necessarily added strictly for strength purposes, but the
fibers can also be used to change physical properties such as toughness, wear resistance,
friction coefficient, or thermal conductivity. Composites have unique combinations of
material properties that traditional monolithic materials do not have.
3.2.2 Component Description
As mentioned previously the focus of this section is on a certain type of
composite, one with a metal as its matrix material. Specifically, the metal matrix
composite that will be discussed here will be an aluminum matrix composite. Figure 9
below is an example of an aluminum-matrix (light areas) MMC filled with Al2O3
agglomerates (dark areas).
Figure 9: Aluminum-matrix MMC filled with Al2O3 agglomerates [45]
Metal matrix composites consisting of either continuous or discontinuous fibers
in a metal result in a material with combinations of very high specific strength and
specific modulus. Therefore, a metal matrix composite can be engineered to be a
suitable alternative for the cylinder block material to meet the requirements that a
traditional aluminum alloy cannot. The reinforcement fibers can be a multitude of
different materials, the most common being silicon carbide, a ceramic. The
reinforcement particles such as alumina, and boron carbide improve the scuffing
resistance to above that of cast iron. Compared to conventional aluminum alloys,
aluminum metal-matrix composites are much stronger at elevated temperatures. This
20
material characteristic is required for the cylinder block application because of the
thermal stresses the combustion process induces on the block.
During manufacturing of the MMC cylinder block, the fiber placement and metal
infiltration are important design parameters that affect the quality of the casting.
Typically the MMCs are made by placing fiber preforms in a mold and squeeze casting
the molten aluminum through the preform. The use of pressure ensures the molten
aluminum completely infiltrates the sponge like fiber preforms. Other researchers have
used an investment casting process to create a sound MMC casting without the use of
high pressure [50]. These infiltration methods have proven beneficial in the promotion
of finer casting grain structure which produces MMC cylinder block castings with
superior material properties.
3.2.3 Past Research and Development
Several automobile manufacturers have been successful in creating metal matrix
composites for production level engine cylinder blocks. Toyota Motor Company was
successful in producing an all-aluminum cylinder block with a MMC liner local to the
cylinder bores. The MMC liner preform consisted of alumina-silica fibers and mullite
particles [28]. Mullite is a refractory that increases the mechanical strength and thermal
shock resistance of the composite. Toyota produced inline four cylinder engine blocks
using this material combination.
Honda motor company was another automobile manufacturer to have success in
producing an all-aluminum engine block with a MMC lined cylinder bore. Honda
manufactured the cylinder blocks by placing cores of carbon fiber in an alumina (Al2O3)
matrix in the casting mold and then poured the molten aluminum around the cores [27].
The MMC cores absorbed the molten aluminum forming the reinforced cylinder bore
surface. After the casting was formed, the inner diameter of the MMC liner is bored out,
so that there is a 0.5-mm thick layer of material remaining. This small thickness of the
reinforced material provides the required wear resistance for the cylinder block
application. Honda used this material in both an inline four cylinder block and a v-
banked six cylinder block.
21
A picture of a MMC liner much like the ones Toyota and Honda created is shown
in Figure 10. The sectioned view on the right shows the smoothness of the machined
surface that the piston rides up and down on. The picture on the left is a graphite
reinforced piston.
Figure 10: Cast Aluminum/Graphite Metal Matrix Composite Cylinder Liner [23]
This particular cylinder block liner is a composite reinforced with graphite particles. The
graphite particles were added prior to the casting process, in which the graphite was
stirred in with the molten aluminum alloy and then poured into the mold. The cost of
producing cast MMCs has decreased rapidly in recent years, especially with the use of
low cost particulate reinforcements such as graphite and silicon carbide [23]. Silicon
carbide and graphite reinforcement composites are commercially available for other
applications.
A company mentioned in the previous section of this project, KS ATAG, besides
developing a hypereutectic Al-Si cylinder block, produced an aluminum matrix
composite suitable for engine cylinder blocks. KS ATAG patented Lokasil® which is an
engineered metal matrix composite whose microstructure consists of an aluminum alloy
matrix with silicon as the reinforcement material. Lokasil® is used as the cylinder block
bore surface material. KS ATAG’s MMC lined cylinder block is manufactured much
like Honda’s cylinder block where a Lokasil® preform is placed in the casting mold and
then molten aluminum is poured into the mold around the preform. The Lokasil®
preform absorbs the molten aluminum and the finished product is a silicon reinforced
22
aluminum cylinder block. KS ATAG’s first generation Lokasil® preforms contained 5%
volume alumina and 15% volume silicon and their second generation Lokasil II®
preforms had only 25% volume silicon [29] with no alumina content.
3.2.3.1 Applications
Toyota used their all-aluminum cylinder block with a MMC cylinder bore for the
seventh generation Celica sports car sold in the US starting in 2000. Production of the
Toyota Celica ended in 2006 but the motor with the MMC lined cylinder block was sold
to Lotus which was used in the Lotus Elise starting in 2005 and is still in production.
The code name for the Toyota 1.8 liter inline four cylinder engine is 2ZZ-GE. Figure 11
is a picture of the 2ZZ-GE’s engine block with a section cut showing the MMC liners for
cylinder bore surface.
Figure 11: 2ZZ-GE MMC Cylinder Block [28]
Toyota wanted to use one of their pre-existing engines for the basic structure that
they then could modify to increase the engine power for the Celica sports car. To do so,
Toyota chose the 1ZZ-FE engine, a 1.8 liter inline four cylinder engine. To use the same
cylinder block geometry from the 1ZZ-FE engine, Toyota needed to engineer a new
solution for developing more power within the same overall dimensions. Using the
principles of internal combustion engine theory, Toyota sought out to increase the piston
bore diameter and decrease the piston stroke, which would increase the engines cycling
capacity but require the distance between cylinder centers to decrease. After extensive
testing Toyota found that a MMC lined cylinder block would allow them to decrease the
23
distance between cylinder bore diameters to 5.5mm for the 2ZZ-GE. Toyota used a
laminar-flow die-casting process with specific control of the process parameters to
achieve sound cylinder block castings.
Honda Motor Company produced two sports cars sold in the US with fiber
reinforced aluminum cylinder blocks, the NSX (1990-2005) sold under their Acura
brand and the Honda S2000 (2000-2009). The Acura NSX was powered by a v-
configuration 6 cylinder engine with fiber reinforced blocks from 1997 to the end of the
its production run in 2005. The Honda S2000 was sold with an inline 4 cylinder engine
with fiber reinforced aluminum cylinder walls for its entire production run. Both were
low volume sports cars that much like the Toyota Celica had compact engines with the
capacity to operate at extremely high revolutions per minute. At higher engine speeds
the cylinder block material must have a higher wear resistance than a standard engine
which the fiber reinforced composite material exhibits.
KS ATAG’s patented Lokasil® material was used in several Porsche engines
sold in US. Lokasil® as the contact surface of the cylinder block has been used in the
2.5 liter and 2.7 liter flat six engines for the Porsche Boxster beginning in 1996 with the
2.5 liter block. Lokasil® has also been used in the 3.4 liter, 3.6 liter and 3.8 liter flat six
engines for the Porsche 911 Carrera beginning in 1997 with the 3.4 liter block. The
Lokasil® lined cylinder blocks were cast using a technique similar to Honda’s MMC
lined cylinder blocks. The process required inserting a preform of the reinforcement
material into the casting mold and allowing the molten aluminum to penetrate the
preform creating the hardened reinforced cylinder bore surface.
3.2.4 Benefits of Fiber or Particle Reinforced Al Alloys
There are several benefits an MMC cylinder block has over the traditional cast
iron lined aluminum cylinder block. MMCs are lighter than cast iron and are more
thermally conductive. This enables manufactures to keep engine displacement down
reducing component costs. Research and development testing by Toyota concluded that
in order to achieve a bore to bore distance of 5.5mm, MMC had the best properties in
terms of (a) between-the-bores rigidity, (b) between-the-bores strength, and (c) head
gasket surface sealing capability compared to hypereutectic Al-Si alloys, thermal spray
24
coatings, and electroplating coatings. The summary of Toyota’s assessment is shown in
Table 3.
Table 3: Comparison of various types of bore designs [28]
With a MMC cylinder block, it is easier to make high performance engine by
increasing the bore diameter without changing the bore stroke. For instance, Toyota
with their 1.8 liter four cylinder 2ZZ-GE engine, was able to produce 26.17% more
horsepower and 4.65% more torque with the same 1.8 liters of displacement as the 1ZZ-
FE that uses cast iron liners [28]. In the case of cast iron liner designs, the maximum
temperature between the bores would exceed the allowable limit. Focusing on high-
temperature strength of the sealing area between the bores, Toyota concluded that the
MMC bore design has an advantage for shorter bore-to-bore distances considering all
aluminum block designs [28]. The MMC bore material has a higher young’s modulus
[Fig. 4, 28], higher tensile strength at elevated temperature [Fig. 5, 28], and higher
compressive strength [Fig. 6, 28] than a hypoeutectic aluminum alloy with similar
mechanical properties as A380.
Lokasil® the MMC, patented by KS-ATAG, provides several advantages over
the traditional approach including weight reduction, a compact design with a minimal
block web width and low thermal deformation. These material properties enable
Lokasil® lined blocks to reduce bore distortion, lower oil consumption, reduced
emissions, and low wear of the engine and its components [22]. According to KS-
ATAG Lokasil® is cheaper than Alusil®, the hypereutectic Al-Si alloy mentioned
earlier, and is easier to process [22]. Basically KS ATAG was able to produce Lokasil®
liners with the proper surface finish without having to chemically etch the surface which
saves time and money.
25
Improved casting techniques by some foundries have provided opportunity for
MMC cylinder blocks to be cast with near net shape geometry in a simple, cost effective
manner. These improvements to how foundries produce MMC cylinder blocks increase
the production rates which is critical for the automotive industry. The casting techniques
include the ability to stringently control the distribution of the constituents, the
reinforcement wetting, and the solidification conditions of the cast MMC [23].
MMC with silicon carbide reinforcements have been developed with good
scuffing resistance and reinforcement distribution. MMC with graphite reinforcements
were also developed with scuffing resistance attributed to the graphite flakes acting as a
solid lubricant during testing.
3.2.5 Drawbacks of Fiber or Particle Reinforced Al Alloys
There are certain material characteristics that are preventing metal matrix
composites from wholly replacing cast iron liners. Engine failure can occur if the MMC
reinforcement particles are not evenly distributed throughout the cylinder bore surface;
the piston ring material can wear away the softer aluminum matrix in the absence of the
reinforcement particles. Once the cylinder bore is worn out, compression is lost and
engine failure will occur. The reinforcement distribution needs to be such that an oil
film can be maintained during operation. Engine durability tests have shown that too
much contact with piston ring material in absence of an oil film will lead to premature
wear and scuffing. After repeated contacts, some durability tests have shown that the
reinforcement material can be broken up if there is too much point contact with the
piston rings.
Problems can also occur if the reinforcement material in the aluminum matrix is
not set properly or is the wrong material type. If the reinforcement material is too hard
the reinforcement can prematurely wear out the ring which is equally as bad as a worn
cylinder bore, because worn rings decrease combustion efficiency and increase fuel and
oil consumption.
The downside to using the MMC block is the complicated and expensive casting
process to get acceptable product. Toyota went through this arduous process with the
2ZZ-GE engine. After much development they were eventually able to obtain castings
26
with near zero defect level in and around the bore areas. Toyota used a laminar-flow
die-casting process with specific control of mold temperature, squeeze pin and gas
discharge [28]. Issues with the casting process included metal infiltration around the
reinforcement fibers, reinforcement distribution, and post-casting machining.
3.2.6 Conclusions
To date the limited production applications of automobiles with fiber reinforced
composite cylinder blocks have been successful in the US market. When the Honda
S2000 sports car debuted in 1999 with a two liter four cylinder engine producing 240
horsepower, it became the most powerful naturally aspirated two liter four cylinder
engine in the world. One of the components that made it possible for Honda to
manufacturer an engine capable of safely producing power at 9,000 RPMs was the fiber
reinforced cylinder block. Going forward, the future implementation of MMC cylinder
blocks on a mass scale is dependent upon the ability of automakers to economically
produce the desired reinforcement distribution by infiltration, the improvement of fiber
matrix bonding, and the development of cost effective material combinations.
27
3.3 Thermal Spray Coating of Aluminum Cylinder Block Walls
A third alternative for replacing the cast iron liners for aluminum alloy cylinder
blocks is to coat the cast aluminum block cylinder bores with a thermal spray of wear
resistant, ceramic or composite material. The sprayed molten metal hardens to form a
suitable wear resistant surface for the aluminum cylinder block.
3.3.1 Process Description
Thermal spraying is the process of melting or heat softening of a material,
fragmenting and propelling the softened material in particulate form against a substrate,
in this case a cylinder block bore. The particles are propelled by a jet of process gases.
The particles accelerate as a confined stream towards the substrate. The heated particles
strike the surface, flatten, quenched, and get bonded to the aluminum. The coating
material is heated by means of an electric arc or combustion gases. In the thermal spray
process, the coating material is fed as a powder, wire or rod. Bonding of the coating to
the casting surface occurs principally by mechanical adhesion and only partially by
metallurgical bonding [30]. Figure 12 is a diagram showing the constituents of a typical
thermal spray process. Coating quality is determined by its porosity, oxide content,
macro and micro-hardness, bond strength and surface roughness.
Figure 12: Scheme of Thermal Spray Coating Process [46]
There are three main types of thermal spray processes suitable for coating
cylinder blocks on a mass production scale. They are electric arc spray, plasma spray
28
and high velocity oxy-fuel spray (HVOF). Table 4 is a comparison of the three major
types of thermal spray processes for aluminum cylinder bore applications.
Table 4: Comparison of Thermal Spray Processes for Aluminum Cylinder Bores [43]
Arc spraying process utilizes two wire electrodes fed into the spray torch and brought
into contact with each other at the front of the spray nozzle. An electrical load is placed
on the wires, one charged positively, and the other negatively, causes the bare metal
electrode tips to melt when they contact one another. An atomization gas such as air or
nitrogen is fed through the center of the spray gun that strips away the melted electrode
metal and propels it at the substrate. The plasma spray process utilizes an electric arc to
disassociate and ionize the atomization gas, which can be argon, nitrogen, hydrogen, etc.
being fed through the center of the spray gun. After the gas passes through the arc its
atomic components recombine, generating plasma that produces a significant quantity of
heat. It is here in the plasma that the coating metal in powder form is introduced into the
flame and propelled at the substrate by the plasma gas and secondary gases. HVOF
utilizes a combination of process gases injected into a combustion chamber of a torch
and ignited to create a high velocity flame. The flame is released through an orifice in
the torch’s nozzle. It is here that the coating material is fed into the flame through
another orifice in the nozzle in powder form. When coating material enters the flame it
melts and is accelerated towards the substrate.
The process of applying a thermal spray coating to a cylinder block is a
multistep process. First, the as-cast cylinder surface is bored to a rough diameter.
Second, the surface is cleaned and fluxed. Next, typically a bonding metal is applied to
29
thermally activate the flux and affect a metallurgical bond with the aluminum surface.
Once the flux and bonding agents have been applied, an iron oxide coating using one of
the thermal spray processes can be deposited. After coating, the cylinder block bore is
inspected for defects. Then it is honed to a final size and finish.
3.3.2 Past Research and Development
There is a number of thermal spray processes used in various industries today.
However, thermal spray technology is relatively new to the automotive world, especially
for coating the surface of cylinder block bores. For an automotive engine block
application thermal spray requires special adaptation to the existing spray systems used
in other industries. Typically the diameters of cylinder bores in modern passenger car
engines are smaller than 100 millimeters. The spray gun head needs to be able to rotate
coaxially in the cylinder bore to avoid having to rotate the cylinder block relative to the
spray gun. The gun head with the plasma generator or the combustion chamber and the
nozzle are mounted at the bottom of a rotating spindle.
Ford Motor Company was one of the early pioneers in the automobile industry
implementing a thermal spray process for cylinder block coating. Ford’s patented plasma
transferred wire arc (PTWA) process, is similar to the traditional arc spray process but
instead of normal gas as the atomizing medium, plasma gas is used. An arc is created
between a tungsten cathode and the copper nozzle acting as the anode. DC power is sent
down the cathode and anode. The power is transferred from the arc to the steel wire
feedstock, which is negatively biased to provide a sufficient conducting path. The
plasma gas is fed through the center of the gun radial ports in the cathode assembly to
produce a vortex and to atomize the molten coating . A secondary high velocity gas with
carefully controlled oxygen content is introduced just past where the plasma stream
intersects the wire arc.
30
Figure 13: Ford Sigma PTWA Apparatus
Source: Ford Motor Company
The molten iron globules combine with the oxygen in the secondary air to form wustite
an oxide of iron. Wustite is 70% harder than the steel matrix on which it forms [14].
The presence of iron oxides, specifically Fe2O3, in the plasma spray coating has been
shown to significantly increase the wear resistance [14]. Figure 13 is a picture of Ford’s
PWTA apparatus applying a coating on the aluminum inline four cylinder block. The
spray head drops down into the cylinder bore and rotates to coat the entire circumference
of the bore.
3.3.2.1 Applications
Ford has used their PWTA process on two US market cars to date. They are the
2011 Ford Mustang Shelby GT500, and the 2009 Nissan GTR. Ford licensed their
process to Nissan for the GTR. Both are high performance sports car, the Mustang has a
5.4 liter eight cylinder engine producing 550 horsepower and the 2012 version of the
GTR has a 3.7 liter six cylinder engine twin turbocharged engine producing 530
horsepower. The coating reduces friction between the piston rings and the cylinder
bores allowing the engine to build rotational speed quicker so that the motors produce
more power. In the Mustang the plasma sprayed coating saves 8.5 pounds weight over
the previous generation which had a cast iron lined aluminum cylinder block [52]. Fuel
economy has also increased 5% over the old model.
31
3.3.3 Benefits of Thermal Spray Coating
Thermal spray coating on aluminum cylinder block bores is the newest of the
four alternatives for replacing cast iron liners. It possesses several key benefits that aid
in the prospect of implementing the technology on a mass production scale. As of today,
only the plasma spray process has been used to coat production vehicle cylinder blocks.
The high thermal energy density available within the plasma used for melting the
powder coupled with the ability to manufacture powder, and design plasma guns with
short spray distances for specific applications has rapidly promoted the use of plasma
spraying [51].
Advantages of plasma sprayed coatings for cylinder bores include the reduction
in the cylinder block bore-to-bore distance, reduction in the friction between the piston
rings and the liner surface, increase in fuel efficiency, and reduction in the oil
consumption. Additionally the wear resistance of the plasma sprayed coating is higher
than cast iron. Recent development in rotating plasma spray guns using plasma-
powder spray process offers a cost-effective versatile high throughput surface
engineering tool for cylinder bore applications [31].
To qualify the plasma spray process for production level vehicles Ford performed
both laboratory and real world testing. It conducted many dynamometer and endurance
testing in the laboratory. Plasma spray lined engines exhibited half the amount of wear
of iron linings in a 300 hour full power endurance test [17]. Ford also put together a
fleet of vehicles with the plasma sprayed cylinder blocks that were driven on various
North American roads in different climates cumulatively for over a million miles. After
testing, Ford’s PTWA process was considered a success with the test data to back it up.
Results from Ford’s testing showed that friction was greatly reduced, on average 6.8%
below the values characteristic of traditional cast iron liners and 14.1% below cast-iron
engines [16]. At large, PTWA coated engines had increased miles per gallon of
gasoline, reduced wear, weight, and cost compared to their cast-iron counterparts [52].
In 2009, the engineers who perfected the PTWA deposition technique received the
National Inventor of the Year Award. The Intellectual Property Owners Education
Foundation cited the energy savings and positive environmental impact of the process.
32
3.3.4 Drawbacks of Thermal Spray Coating
The majority of the issues regarding thermal sprayed coatings for cylinder blocks
deal specifically with process types and not thermal spray in general. The most basic of
the drawbacks of the thermal spray coatings is the weakness of the bond between the
coated material and the aluminum. If the coating is not applied properly, over time de-
lamination can occur, stripping away the coating and exposing the soft aluminum block
material. Once that happens, premature wearing occurs and eventually the engine will
lose compression resulting in engine failure.
Additionally an issue with thermal spray processes pertains to any high velocity
spray coating. The coated material deposited on the substrate has a splatter morphology
from the high velocity impact of spherical particles striking the surface. Inconsistency in
coating properties occurs when the particles splatter against the substrate generating
pores in the coating. This can lead to cracking of the coating. Splatter morphology is
more of a concern with HVOF thermal spray because it utilizes high speeds to atomize
the coating material and with the short spray distances inside the cylinder bore splatter
morphology is more prevalent. In addition, during the application of the HVOF thermal
spray overheating of the aluminum cylinder block can occur because the particles are
still extremely hot when they bond with the substrate. Overheating can damage the
block by distorting it and possibly even changing the microstructure of the aluminum.
Another concern with thermal spray coatings is the initial capital investment of
the spray equipment. In order to coat cylinder blocks, existing production lines in the
plant will need to be either modified or new ones created to allow for the cylinder blocks
to be prepped and coated with a thermal spray process. The automaker would then be
relying on volume and reduction in cost per unit to ensure a timely buyback period.
33
3.3.5 Conclusions
Even though there is only a handful of production vehicles with cylinder blocks
that have been coated with a thermal spray process to date, plasma spray coating has
emerged as a promising alternative to cast iron liners. The process has already proven
itself worthy through extensive testing and market adoption. The coating material itself
is rather inexpensive. Therefore most of the burden of implementing the process for the
automaker is upfront equipment and logistic costs. Due to the high deposition efficiency
(over 80%) and high feed rates, the entire process can be completed in under 60 seconds
making it appealing on a mass market production level.
34
3.4 Electroplating Aluminum Cylinder Block Bore Surface
The fourth possible alternative to the replacement of cast iron liners for aluminum
engine blocks is to electroplate the cylinder bore walls with high hardness, wear resistant
materials. The electroplating processes used commercially or in the research and
development stage are nickel ceramic composite (NCC) coatings, and plasma
electrolytic oxidation (PEO) coatings. PEO coatings are also known as micro-arc
oxidation (MAO) coatings.
3.4.1 Process Description
Electroplating is a process where electrically charged metal ions in solution are
moved by an electric field to coat an electrode. The plating process uses electrical
current to reduce cations of a desired material from a solution and coat a conductive
object, in this case a cylinder block, with a thin layer of material [47]. Thus, the
deposition is the process of coating thin layer of one metal on top of a different metal to
modify its surface properties. One type of electroplating which is applied using the
aforementioned process for cylinder bore surface modification is NCC plating, also
referred to as NCC coating. NCC is a plating with nickel as the base material containing
particles of silicon carbide dispersed throughout, shown in Figure 14. The substrate in
this case is aluminum.
Figure 14: Nickel Silicon Carbide composite applied to a cylinder bore [36]
35
During the electroplating process the cylinder block is immersed in a bath of electrolyte
which typically consists of a salt or alkali solution such as potassium hydroxide (KOH).
The second type of electrolytic process used for coating cylinder block bore
surfaces is plasma electrolytic oxidation (PEO), also known as micro-arc oxidation
(MAO). Potentials of over 200 volts are applied between the two electrodes [37]. The
volts can be supplied as a continuous or pulsed direct current or pulsed alternating
current. Figure 15 is a diagram of the components of a typical PEO process.
Figure 15: Plasma Electrolytic Oxidation Process [48]
Plasma electrolytic oxidation is similar to conventional anodizing in that an appropriate
electrical potential is applied to aluminum to increase the thickness of the oxide layer on
the surface of the aluminum. Pure aluminum naturally forms a tough, wear resistant
oxide layer when first subjected to ambient air. It provides moderate protection against
corrosion. This oxide layer is common alumina and has a chemical formula Al2O3. In
conventional anodizing, this layer of oxide is grown on the surface of the aluminum by
applying an electrical potential while the part is immersed in an acidic electrolyte [37].
In plasma electrolytic oxidation, higher potentials are applied compared to
conventional anodizing. In the PEO of aluminum at least 200 volts must be applied.
This locally exceeds the dielectric breakdown potential of the growing oxide film, and
discharges occur. These discharges result in localized plasma reactors, with conditions
of high temperature and pressure which modify the growing oxide. Processes include
melting, melt-flow, re-solidification, sintering and densification of the growing oxide.
One of the most significant effects is that the oxide is partially converted from
36
amorphous alumina into crystalline forms such as corundum ( -Al2O3) which is much
harder [38]. Figure 16 is a scanning electron micrograph (SEM) of the splatter
morphology of a PEO coating on an aluminum substrate.
Figure 16: SEM micrograph of a typical PEO coating on aluminum [53]
Alternative NCC coatings include boron nitride (BN) for its self-lubricating
properties and silicon nitride (Si3N4) for its combination of wear resistance and self-
lubrication [34]. Self-lubricating properties afforded by the use of BN and Si3N4 also
offer greater flexibility in selection of mating materials while increasing the potential to
tighten tolerances between mating components [34].
3.4.2 Past Research and Development
Mahle developed a hard nickel based coating for the apex seals for the Wankel
motor in the early 1960s. Engineers at Mahle realized early that the nickel based coating
could also be applied to conventional engine cylinders, cylinder liners and sleeves to
reduce wear and improve lubricity [36]. The coating was named Nikasil®. It became a
registered trademark of the Mahle Company in 1967.
Nikasil® is an electrodeposited oleophilic nickel matrix silicon carbide coating
used on production engine cylinder bores. Nickel adheres to the parent bore material
and supports the silicon carbide particles that provide the necessary wear resistance and
hardness that is required for the cylinder block application. Silicon carbide is a very
hard abrasive material with a hardness second only to diamond [35]. The oleophilic
37
feature of Nikasil® gives it a natural tendency to absorb oil, which in turn helps the oil
retention of the coating increasing the life of the coating [36].
The process for depositing the oxide coating on aluminum anode under an arc
discharge condition was first reported by Markov and co-workers in the 1970s [39].
Many other researchers worked with the plasma electrolytic oxidation process
throughout the 1980s as well. It wasn’t until the research contributions by Yerokhin et
al. of Tula State University in the 1990s that the PEO process gained worldwide
recognition as an eco-friendly technology for depositing the tribologically superior
ceramic coatings on aluminum and its alloys [39]. A commercialized version of the
PEO process that Yerokhin et al. started is called Keronite. This process was developed
by a company in the UK working with the Russian originators. The Keronite process
creates a fused ceramic layer on the surface of the aluminum that is self-regulating, and
has a uniform thickness which includes the edges of the component.
3.4.2.1 Applications
Mahle initially developed Nikasil® to coat the rotary engine apex seals when the
Wankel motor was gaining popularity in the automotive industry in the late 1960s and
early 1970s. BMW, Porsche, Ferrari and Jaguar were some of the automakers to use
Nikasil® on production engines. During the 1990’s, in Europe, BMW coated several
production vehicle cylinder blocks with Nikasil® including two generations of 3 series
and 5 series, and one generation of both the 7 series and the Z3. Unfortunately because
of the high sulfur content in the gasoline sold in the US, BMW could not use Nikasil® in
US market vehicles. The low quality high sulfur gasoline caused some Nikasil® coated
cylinders to break down over time, causing costly engine failures. Another nickel based
coating, NiCom® was developed by US Chrome Corporation in the early 1990’s with
improved material characteristics. Porsche has maintained the use of Nikasil® in their
high performance variants of their 911 model.
Overall nickel ceramic coatings have been successful in high performance low
volume automotive engines due to their superior performance and lower deposition rate,
hence better control, compared to those of thermal spray technologies [43]. Before
38
NASCAR switched to Compacted Graphics Iron cylinder blocks, NCC was used to coat
the cylinder blocks for its lubricity and wear characteristics.
3.4.3 Benefits of Electrolytic Coating Process
There are numerous benefits that the different electrolytic coating processes have
over the traditional approach of lining aluminum cylinder blocks with cast iron sleeves.
The two main processes, NCC and PEO/MAO coatings, have properties that are
characterized by high hardness, high corrosion resistance, high temperature wear and
scuff resistance and low friction coefficients [34].
For the application of coating cylinder block bore surfaces in addition to high
hardness and corrosion resistance, the most effective property of NCC coating is its low
frictional coefficient. NCC is capable of contributing significantly to the reduction of
friction loss between sliding components. The friction coefficient of NCC coatings fall
in the 0.08-0.12 range, even under non-lubricated conditions [34]. Figure 17 compares
the frictional coefficients of several different electroplating materials. Hard chrome was
the original plating material for cylinder blocks but as the chart shows, the newer, more
advanced plating materials, have much lower frictional coefficients.
Figure 17: Comparison of surface frictional coefficients for NCCs and Cr [34]
When a NCC coating is applied properly, it will easily last the entire life of the
automobile. On a street-driven production vehicle, the coating can last upwards of
39
several hundred thousand miles because the coating wears very slowly compared to cast
iron, anywhere from 3 to 10 times better based on the application [36]. Depending upon
the alloy used and thickness of the coating applied on aluminum the hardness of
Keronite, a coating applied using the PEO/MAO technique, can reach 2,000 on the
Vickers Hardness scale, at least three times harder than hard anodizing [40]. In addition
to its high hardness, Keronite has a much stronger bond with the substrate material than
coatings applied with a plasma spray process.
When Nikasil® is used to coat the cylinder block bore surface this allows the
engine designers to reduce the distances between cylinder bore diameters with tighter
tolerances. It creates the opportunity for manufacturers to increase engine displacement
without increasing the overall size of the cylinder block.
3.4.4 Drawbacks of Electrolytic Coating Process
Unfortunately the electrolytic coating processes suffered through a very public
display of failure in the US in the 1990’s. The problem occurred specifically with
Nikasil®. BMW used Nikasil® to line the cylinders of several of their production
engines in the nineties. The problem arose from the fact that gasoline sold in the US has
a high concentration of sulfur as compared to Europe where the gasoline is basically
sulfur free. The sulfur broke down the nickel based coating causing “leak down” which
would result in a rough idle and eventually total engine failure. During engine testing
BMW used only sulfur-free gasoline so they had no idea that the problem was going to
occur before the cars made their way to the market.
Another drawback of electro-deposition processes is that the process is complex
and costly. Applying the coating to selective areas of the cylinder block requires either
a more complicated fixture that can apply localized deposition or extensive and elaborate
masking. The raw materials, specifically nickel, of the electrodeposited coatings are
more expensive relative to cast iron which hinders their ability to be used on mass
production automobiles. Another part of the manufacturing process adds to the overall
cost is the special machining tools needed to hone the coating to its final thickness. The
coatings have a hardness that requires special diamond tipped cutting tools for the
honing process.
40
3.4.5 Conclusions
The key aspect of the potential widespread use of electrolytic coatings for
aluminum cylinder blocks for the US market is what happens to the sulfur content in
gasoline. Currently, Europe has all but eliminated sulfur from its gasoline, while the US
gasoline can still have up to 95 parts per million (ppm). In the spring of 2010, the US
Environmental Protection Agency (EPA) was instructed by the Obama Administration to
research the effect of sulfur levels in gasoline on greenhouse-gas emissions. To date, the
EPA hasn’t reached any conclusions or proposed any new rules for lower-sulfur
gasoline. If the EPA does impose new regulations in the future for sulfur free gasoline
in the US, then that would pave the way for electrolytic coatings to be considered for
widespread use.
41
4. Comparative Analysis
Up to this point in the project information that pertains to each alternative has been
discussed in great length. Using that information a comparative analysis of the
alternatives is as follows:
Category Rating System
5 = Excellent
4 = Above Average
3 = Average
2 = Below Average
1 = Poor
4.1 Comparison Categories
4.1.1 Previous Applications
Cast Iron = 5 Hypereutectic Al-Si = 2 Fiber Reinforced = 1 Thermal Spray = 1 Electroplating = 2
Citing previous applications of the alternatives gives a basis for the confidence that the
automotive industry has in the alternative method for replacing the cast iron liners used
with aluminum cylinder blocks. Until the recent development with the increased CAFÉ
mpg average, the majority of the production automobiles with aluminum engine blocks
have had cast iron cylinder liners. There are examples of larger passenger automobiles
with hypereutectic Al-Si alloys in Europe. Most of the production model vehicles use
Alusil®, an alloy patented by KS ATAG in Germany. On a comparative basis, there are
fewer production models with fiber reinforced cylinder blocks than hypereutectic Al-Si
cylinder blocks. Toyota and Honda have had success using fiber reinforced composite
materials on several US market sports cars. Thermal spray technologies are a newer
alternative. Only two US market automobiles have thermally sprayed cylinder bore
surfaces. Lastly, electroplating has had success in low volume sports cars for many
years. There were production models in the US that used Nikasil®, one type of
electroplating, in the 1980’s. However, there were problems with the performance
42
because of the sulfur content in US fuel. Sulfur would attack the plating and premature
engine failure would occur.
4.1.2 Wear Resistance
Cast Iron = 4 Hypereutectic Al-Si = 3 Fiber Reinforced = 3 Thermal Spray = 4 Electroplating = 4
Resistance to wear from a sliding surface is one of the key characteristics that a cylinder
block material needs to exhibit. The harsh environment of an internal combustion
engine can easily damage softer materials. Several researchers have performed
extensive wear resistance testing of the alternatives for cast iron for cylinder block bore
material. The results show that cast iron’s wear resistance with its tendency to hold
lubricating oil because of its porous nature is excellent. Cast iron also showed an ability
to resist wear at elevated temperatures better than the alternatives. Both thermally
sprayed oxide coatings and electroplated nickel ceramic coatings demonstrated excellent
wear resistance. The problem being that the two coatings are so hard, they can damage
the piston and piston rings, more so with the thermally sprayed oxide coatings. The fiber
reinforced and hypereutectic Al-Si alloys performed well in testing with acceptable wear
resistance. The fiber reinforced composites and hypereutectic Al-Si don’t rate as highly
compared to the alternatives because their wear resistance is based on the dispersed
particles of the additive elements that give the alternative materials sufficient wear
resistance. If the dispersed particles are large enough and evenly mixed, wear can occur
where large areas of the softer parent aluminum material is prevalent.
4.1.3 Scuffing Resistance
Cast Iron = 5 Hypereutectic Al-Si = 3 Fiber Reinforced = 3 Thermal Spray = 4 Electroplating = 4
A cylinder block material’s ability to resist scuffing is another important characteristic.
As discussed earlier, scuffing occurs right after the engine is turned on and the cylinder
block is still cold. The importance of scuffing has led several researchers to develop
scuffing resistance testing comparing the alternative materials to cast iron for cylinder
block bore surfaces. The scuffing resistance testing had similar results as the wear
resistance testing, which would be expected because both tests have similar setups and
43
rely on similar material behavior. Simply stated, the test involves a reciprocating load
that is cycled over the test material to emulate the action of the piston and piston rings on
the cylinder bore surface. Material/scuffing is observed and recorded. Cast iron again
demonstrated the best scuffing resistance followed by the nickel ceramic coating applied
by the electroplating process. The thermally sprayed oxide coating also performed well
in scuff resistant testing. Therefore, it could be summarized that the hypereutectic Al-Si
alloy, the fiber reinforced composite Al alloy, and the thermal sprayed oxide coating
demonstrated equal and sufficient scuffing resistance.
4.1.4 Thermal Conductivity
Cast Iron = 1 Hypereutectic Al-Si = 4 Fiber Reinforced = 4 Thermal Spray = 3 Electroplating = 3
Thermal conductivity is the property of a material’s ability to conduct heat. The thermal
conductivity of the cylinder block material is important in controlling the operating
temperature of the internal combustion engine. The cylinder blocks ability to gain or
lose heat impacts the efficiency of the combustion process which in turn impacts the
engines fuel efficiency and emissions. The more thermally conductive the cylinder
block material is, the easier it is for the cooling system to maintain a constant
temperature through the material thickness. This eliminates the possibility of hot spots
in the cylinder block which over time can lead to cracking and failure of the block.
Aluminum is three times more thermally conductive than cast iron. The hypereutectic
Al-Si alloys and the fiber reinforced composite alloys have better thermal conductivity
than cast iron. The material used in the thermal spray process and the electrochemically
deposited material are not as thermally conductive as the two aluminum alloys are.
However, they are better than the cast irons. The coating thicknesses are much thinner
than the cast iron liners which allows for easier transfer of heat between materials.
4.1.5 Friction between cylinder block and piston rings
Cast Iron = 3 Hypereutectic Al-Si = 3 Fiber Reinforced = 3 Thermal Spray = 5 Electroplating = 4
44
The friction between the cylinder block bore material and the piston rings is the single
biggest contributor to the loss of power in an internal combustion engine. Limiting this
friction goes a long way in increasing the fuel efficiency of an automobile outside of
reducing vehicle weight. The best alternative for reducing friction is the thermally
sprayed coating material. The coating is extremely hard and its ability to retain a layer
of oil for lubrication during operation is key for reducing the coefficient of friction. The
electrodeposited material with its high hardness is another good candidate material for
reducing friction. The two aluminum alloys, the hypereutectic Al-Si and the fiber
reinforced composite, exemplify satisfactory results during testing. Both material
performances are dependent upon the hardening particles dispersed in the parent
aluminum. The more evenly the particles are dispersed in the aluminum, the better the
material can provide a smooth sliding surface while maintaining the ability to retain oil
for lubricating purposes. Cast iron is the basis of the comparison and demonstrates
acceptable performance.
4.1.6 Fuel Economy
Cast Iron = 3 Hypereutectic Al-Si = 4 Fiber Reinforced = 4 Thermal Spray = 4 Electroplating = 4
Fuel economy or fuel consumption is the measurement of how much fuel the
automobile’s internal combustion engine uses over a given distance. In the US the unit
of measure is mile per gallon. This category is important to validate the assessment of
replacing cast iron liner on aluminum cylinder blocks. Engine fuel economy will
become more important to automakers in the near future due to the increased
government CAFÉ standards. Researching the alternatives has led to the conclusion that
all four candidates will increase the fuel economy of a given engine by replacing the cast
iron liners. Typically the aluminum alloys and the coatings can increase the vehicle’s
fuel economy on average by 3 to 5%.
45
4.1.7 Engine Emissions
Cast Iron = 3 Hypereutectic Al-Si = 4 Fiber Reinforced = 4 Thermal Spray = 4 Electroplating = 4
Engine emissions are the byproducts of the automobile engines combustion processes
that exit the tailpipe of an automobile and enter the atmosphere. The subject of
automobile emissions has become more important in recent times due to the increased
awareness of their impact to the planet’s ecosystem. The Government’s increasing the
CAFÉ standards solves multiple issues, it decreases our country’s dependency on
foreign oil, but also it decreases the amount of automobile emissions which has a
positive impact on the environment. The results here for this comparison are the same as
the fuel economy results. Each alternative holds a slight advantage over the previous
solution of lining the cylinder bores with a cast iron sleeve. This stems from the fact that
each alternative slightly increases the fuel efficiency of the engine which will decrease
the engine emissions by a small amount.
4.1.8 Manufacturing Costs
Cast Iron = 5 Hypereutectic Al-Si = 3 Fiber Reinforced = 3 Thermal Spray = 3 Electroplating = 2
The alternative material’s production costs are those associated with the material
procurement, casting process, specialized tooling, coating process (where applicable)
and post-cast machining. The costs associated with using cast iron sleeves with
aluminum alloy cylinder blocks are considered baseline. To date, the cast iron liners are
the cheapest solution. Each one of the alternatives has associated costs that increase the
total production cost beyond the baseline costs. The perfect hypereutectic Al-Si alloy
for the cylinder block application has not been commercialized to date. This means that
if an automobile manufacturer wants to use a hypereutectic Al-Si for their cylinder
blocks, they must incur the development costs of producing a new hypereutectic Al-Si
alloy. Hypereutectic Al-Si alloys are difficult to cast with the right consistency of
primary silicon particles throughout the bore surface. Both hypereutectic Al-Si alloys
and fiber reinforced composite Al alloys require expensive post cast machining.
Thermal Spray coatings require additional equipment costs of procuring the machine that
sprays the coating. Electrochemical deposition coatings also require the procurement of
46
the apparatus that will apply the coating. The material used in electroplating is more
expensive than cast iron.
4.1.9 Engine Performance
Cast Iron = 4 Hypereutectic Al-Si = 3 Fiber Reinforced = 4 Thermal Spray = 4 Electroplating = 4
Engine performance for purposes of this comparison relates to how each alternative
affects engine longevity, power production and maintenance. The two coating
alternatives, thermal spray and electroplating both exhibit excellent performance at
elevated temperatures allowing for automakers to design the engine to operate at a
higher compression ratio. That creates a hotter combustion process putting more stress
on the cylinder block and other engine components. The fiber reinforced metal matrix
composites also exhibit excellent performance at elevated temperatures. There are
several examples of fiber reinforced composites, plasma sprayed iron oxide, and nickel
ceramic carbide used in high performance applications. In terms of longevity and
maintenance, cast iron liners have proven to be a perfectly viable solution as a result of
being used consistently for many years.
4.1.10 Mass Production Feasibility
Cast Iron = 5 Hypereutectic Al-Si = 4 Fiber Reinforced = 3 Thermal Spray = 5 Electroplating = 3
The alternative choices to using cast iron liners for aluminum cylinder blocks may be
feasible on a mass production scale. It’s an important parameter in this comparison.
Currently in the US, cast iron liners are used in the majority of the production vehicles
sold with aluminum cylinder blocks. Assuming that in the future the automakers need to
move away from cast iron liners because of the increased fuel economy standard, plasma
sprayed coatings have the greatest ease of being implemented on a mass production
scale. This is a result of thermal spray coatings having a combination of cheaper
material cost and short manufacturing time relative to the other alternatives.
Hypereutectic Al-Si alloys and fiber reinforced composites suffer from increased
material costs. Electrolytic process coatings take a considerable amount of time to
achieve the proper coating thickness in the bath.
47
5. Summary
5.1 Results of Comparison
The results of the comparison in this paper are based on a combination of research
data and engineering judgment. The objective of the project was to assess the validity of
selected alternatives replacing the cast iron liners that are used to fortify aluminum
cylinder blocks for passenger cars. Ten different parameters were used to compare the
validity of the alternatives against one another and against cast iron liners. The results of
the comparison are summarized below in Table 5.
Table 5: Results of Comparison
Current Design Score out
of 50*
Cast Iron Liners with Hypoeutectic Al-Si Cylinder Block 38
Alternative Design
Hypereutectic Al-Si Alloy Cylinder Block 33
Fiber Reinforced Aluminum Matrix Composite Cylinder Block 32
Thermal Spray Coating on Hypoeutectic Aluminum Bore Surface 37
Electrochemical Deposition Coating on Hypoeutectic Aluminum
Bore Surface 34
* Score is the sum of rankings assigned in the ten categories
The results show that cast iron liners based on the parameters of the comparison
is still the best option for today’s modern passenger car cylinder blocks. As it was cast
iron liners rated very well in terms of previous applications, cost, and mass production
possibility including being the current industry standard. The best alternative proved to
be thermally sprayed cylinder bore coatings. Thermal spray coatings rated well in
minimizing frictional losses between the cylinder surface and the piston rings and mass
production possibility. Electrochemically deposited coatings proved to be the second
best alternative in the comparison. Electrochemical deposition coatings are of high
quality and high wear and scuff resistance. But they suffer from production cost issues.
48
Nickel used in many of the electrochemically deposited coatings is more expensive than
cast iron. Also the post cast machining processes for an electroplating can be
expensive. Hypereutectic Al-Si alloy and fiber reinforced aluminum matrix composite
cylinder blocks came in right behind electrochemically deposited coatings in the
comparison with one point separating each one from another. Hypereutectic Al-Si alloy
cylinder blocks performed well in most categories but did not perform exceptionally
well to establish it ahead of the other alternatives. Fiber reinforced aluminum matrix
composite cylinder blocks or cylinder liners had very similar results as hypereutectic Al-
Si alloy cylinder blocks which is not surprising because the two approaches have similar
material characteristics. Table 7 summarizes the applications of each alternative to date.
49
5.2 Future of Alternatives
The United States federal government has proposed legislation that would require
automakers to have a vehicle fleet with an average mpg of 35.5 by 2016. The objective
of the legislation was to reduce our dependency on foreign oil and to reduce vehicle
emissions. The new legislation will force automobile manufacturers to make design
decisions on future vehicles based on how the design affects fuel economy performance.
As stated previously, the two major factors that impact automobile fuel economy are
vehicle weight and frictional losses. Therefore, it is up to the automobile manufacturers
to find ways to increase automobile fuel economy without drastically increasing the cost
of the vehicle in order to stay competitive in the market.
In the future the MPG requirement for passenger cars will reach a level where cost
is not the determining factor for the incorporation of certain designs because the increase
in fuel economy performance from the design is a necessity. One such design change
that in the future will be made based heavily on fuel economy performance is replacing
the cast iron liners used with aluminum engine blocks. Currently, the cast iron liners are
the best solution because cast iron is a cheap readily available material and meets the
requirements of a cylinder block bore surface material. In the future the cast iron liners
will be replaced because cast iron doesn’t have the capacity to increase vehicle fuel
economy and reduction of emissions that are inherent to the alternatives.
Another one of the determining factors that was used in the comparison that
wouldn’t have the same impact in the future is previous applications. Once the MPG
requirement reaches that level where the cast iron liners must be replaced, the
automobile manufacturers will no longer be able to decide on a path that they already
feel comfortable with and had success with in previous applications, the cast iron liners.
The manufacturers will need to spend the research and development resources and prove
to themselves that they can implement a new more fuel efficient solution to the
aluminum cylinder block bore material problem.
A third determining factor that was used in the comparison that wouldn’t have
the same impact in the future is mass production feasibility. Again, once the MPG
requirement reaches the level where the cast iron liners must be replace, the automakers
50
will need to spend the resources developing new manufacturing techniques that will get
them the required production rates that are necessary for passenger cars.
Once the manufacturing cost, previous applications, and mass production
feasibility categories are removed from the future MPG requirement comparison the best
solution is a thermally sprayed coating on the cylinder block bore surface. The results of
the comparison are summarized in Table 6 below.
Table 6: Results of Comparison based on Future MPG Requirements
Current Design Score out
of 35*
Cast Iron Liners with Hypoeutectic Al-Si Cylinder Block 23
Alternative Design
Hypereutectic Al-Si Alloy Cylinder Block 24
Fiber Reinforced Aluminum Matrix Composite Cylinder Block 25
Thermal Spray Coating on Hypoeutectic Aluminum Bore Surface 28
Electrochemical Deposition Coating on Hypoeutectic Aluminum
Bore Surface 27
* Score is the sum of rankings assigned in seven categories
The score above is the sum of the rankings from the remaining seven categories used in
the original comparison. The seven remaining categories are attributes that characterize
the performance of the alternative regardless of cost, previous applications, and mass
production feasibility. Therefore, in the future, as the MPG requirement continues to
increase, the best alternative to cast iron liners is to coat the aluminum cylinder bore
surface with a wear resistant material applied using a thermal spray process.
Table 7: Applications of the Candidate Alternatives for Cast Iron Liners
Candidate Alternative
Prior/Current Application Cylinder
bore
surface
properties
Opportunity
for mass
production Volume Cost
Hypereutectic Al-Si
alloy cylinder blocks
Alusil® Large engine (8 cylinders and more)
High Med Med High European passenger cars
Mercosil Outboard motors, small European cars High Med Med High
Cylinder bore
coatings applied
with a thermal spray
process
plasma transfer wire arc Ford Mustang Shelby GT500, Nissan
GTR Low Low Med High
High velocity oxy-fuel None to date n/a High High Low
Rotating air plasma spray None to date n/a Low High High
Fiber reinforced
aluminum matrix
composites
Silicon carbide fiber reinforced
aluminum matrix composite
Toyota Celica, Lotus Elise, Honda
Prelude and S2000, Acura NSX Low Med Med Low
Lokasil® Porsche Boxster, Porsche 911 Med Med Med Med
Cylinder bore
coatings applied
with an electrolytic
process
Nickel ceramic composite Numerous Porsche, BMW, Jaguar,
Ferrari models High High High Low
Plasma electrolytic oxidation None to date n/a Low High Med
6. References
1. Financial Trend Forecaster. Inflation Adjusted Average Annual Gasoline Prices
1918-2009. Copyright 2010. Chart prepared by Timothy McMahon. Updated
7/21//2010
2. Inventory of U.S. Greenhouse Gas Emissions and Sinks: 1990-2008. U.S.
Environmental Protection Agency. April 15, 2010
3. Allen, Mike & Javer, Eamon. Obama announces new fuel standards.
www.politico.com. May 19, 2009
4. Naranjo, Robert D., HuangFu, Her-Ping, Gwyn, Mike. Castings Drive Fuel
Efficiency. Modern Casting; Sep 2004; 94, 9; ABI/INFORM Trade & Industry
pg. 20
5. Grosselle, Fabio, Timelli Giulio, Bonollo, Franco, et. Al. Correlation between
microstructure and mechanical properties of Al-Si diecast engine blocks.
Metallurgical Science and Technology. Vol 27-2 – Ed 2009
6. Mid-Atlantic Casting Services. A Guide to Aluminum Casting Alloys.
www.Mid-AtlanticCasting.com
7. Valtierra-Gallardo, Salvador et al. Wear-Resistant Aluminum Alloy for Casting
Engine Blocks with Linerless Cylinders. Patent Application – Publication
Number: WO 2008/053363 A2. 8 May 2008.
8. Popoola, Oludele O., Matthew J. Zaluzec, Kimberly A. Lazarz, and Armando M.
Joaquin. Method of Simultaneous Cleaning and Fluxing of Aluminum Cylinder
Block Bore Surfaces for Thermal Spray Coating Adhesion. Ford Global
Technologies, Inc. assignee. Patent 6187388 B1. 13 Feb. 2001.
9. ASM Handbook Alloy Phase Diagrams. Volume 3, ASM International, Materials
Park, OH, 2003.
10. Barbezat G., “Application of Thermal Spraying in the Automotive Industry.”
Surface & Coatings Technology 201 (2006): 2028-031. 28 April 2010.
11. Kim, M.R., R.W. Smith, and R.C. McCune. “High Deposition Rate Coating of
Aluminum Cylinder Bores” Thermal Spray 2001: New Surfaces for a New
Millenium; Proceedings of the 2nd
International Thermal Spray Conference, 28-
53
30 May, 2001, Singapore. Ed. Christopher C. Berndt. Materials Park, OH. ASM
International, 2001.
12. Beddoes, J. and Bibby, M.J., Principles of Metal Manufacturing Processes.
Elsevier, N.Y., May 1999
13. Zaluzed, Matthew J., Robert C. McCune, Oludele O. Popoola, James R.
Baughman, and John E. Brevick. Method of Depositing and Using a Composite
Coating on Light Metal Substrates. Ford Motor Company, assignee. Patent
5592927. 14 Jan 1997.
14. Bobzin, K., F. Ernst, J. Zwick, T. Schlaefer, D. Cook, K. Kowalsky, K. Bird,
D.H. Gerke, R. E. Sharp, K.R. Raab, and S. Lindon. “Thermal Spraying of
Cylinder Bores with the PTWA Internal Coating System.” Proceedings of the
2007 Fall Technical Conference of the ASME Internal Combustion Engine
Division: October 14-17, 2007, Charleston, South Carolina. New York, NY.:
American Society of Mechanical Engineers, 2008.
15. Hartfield-Wunsch, S. E., and S. C. Tung. “The Effect of Microstructure on the
Wear Behavior of Thermal Spray Coatings.” Thermal Spray: Industrial
Applications: Proceedings of the 7th
National Thermal Spray Conference.
Boston. Materials Park, Ohio: ASM International, 1994. 24-29.
16. Millikin, Mike, ed. “Ford Developing Thermally Sprayed Nano-Coating for
Cylinders to Reduce Friction, Support Lighterweight Construction.” Green Car
Congress. BioAge Group, 17 Apr. 2008.
17. Barbezat, G., “Low-Cost High-Performance Coatings Produced by Internal
Plasma Spraying for the Production of High Efficiency Engines.” Thermal Spray
2003: Advancing the Science and Applying the Technology: Proceedings of the
2003 International Thermal Spray Conference, 5-8 May, 2003, Orlando, Florida.
Materials Park, OH: ASM International, 2003. 141-142.
18. Cook, David, Ing C. Verpport, K. Kowalsky, and R. Dicks. “Thermal Spray of
Cylinder Bores with the Ford PTWA Process.” Association of German Engineers
(2003).
19. Wojdyla, Ben. “The Ford Engine Technology Good Enough for the Nissan GT-
R.” Jalopnik 10. Feb 2010.
54
20. Donahue, Raymond Ph.D., Philip A. Fabiyi. “Manufacturing Feasibility of All-
Aluminum Automotive Engines Via Application of High Silicon Aluminum
Alloy”. Society of Automotive Engineers, Inc., 2000.
21. Bolling, Gustaf F., Jean Cisse. Aluminum Silicon Alloys. Ford Motor Company,
Assignee. Patent 3895941. 22 July 1975.
22. Kolbenschmidt Pierburg North America. “KS Aluminum Technology develops
advanced cylinder bore technologies.” Press Release. 03 April 2006.
www.pierburg.com
23. Rohatgi, Pradeep. Cast Metal-Matrix Composites. Metals Handbook 9th
Ed. Vol.
15 - Castings. The University of Wisconsin-Milwaukee. Pp. 840-853.
24. Kolbenschmidt Pierburg. “Low-pressure die cast cylinder blocks – the optimum
for SI engines in V arrangement and high-performance diesel engines (for
passenger cars).” Press Release.
25. Doty, Herbert William. Aluminum Alloy for engine blocks. General Motors
Corporation, Assignee. Patent 6921512. 26 July, 2005.
26. Rooy, Elwin L., Aluminum and Aluminum Alloys. Metals Handbooks 9th
Ed.
Vol. 15 – Castings. Aluminum Company of America. Pp. 744, 758
27. Vasilash, Gary S. “NSX: Aluminum Intensive.” Automotive Design and
Production. Gardner Publications, Inc. www.autofieldguide.com. June 1999.
28. Takami, Toshihiro, et. al. Toyota Motor Corp. Masago Yamamoto, Toyota
Central Research and Development Labs, Inc. “MMC All Aluminum Cylinder
Block for High Power SI Engines.” Society of Automotive Engineers, Inc., 2000.
2000-01-1231.
29. Evans, Alexander. Christopher San Marchi, Andreas Mortensen. “Metal Matrix
Composition in Industry – An Introduction and a Survey.” Kluwer Academic
Publishers. Norwell, Massachusetts. Copyright 2003. Pp. 241-243
30. Walton, Charles F., Coating of Castings. Metals Handbook 9th
Ed. Vol. 15 –
Castings. Pp. 563
31. Wuest, G. et al., “The Key Advantages of the Plasma-Powder Spray Process for
the Thermal Spray Coating of Cylinder Bores in Automotive Industry”, SAE
International Congress & Exposition, February 1997. Pp. 33-43.
55
32. Bobzin, K., F. Ernst, K. Richardt, et. al. “Thermal Spraying of Cylinder Bores
with the Plasma Transferred Wire Arc Process” Surface & Coatings Technology
202 (2008) 4438-4443
33. Praxair Surface Technologies. “Hard Facts: HVOF Thermal Spray Process.”
Copyright 2005 Praxair S.T. Technology, Inc.
34. Funatani K., K. Kurosawa, et. al. “Improved Engine Performance Via Use of
Nickel Ceramic Composite Coatings (NCC Coat).” SAE Technical Paper Series
940852. February 28, 1994. Pp. 89-96
35. Carley, Larry. “Machining New Metals – Nickel Silicon Carbide Coatings”
Engine Builder Magazine, Babcox Media. October 1, 2008.
36. Goodman, John. “Nikasil® and Alusil® – A primer on some of the most
common specialty coatings and cylinder materials found in a small displacement
engines.” Engine Professional. Oct-Dec 2008. Pp. 18-22
37. “Plasma Electrolytic Oxidation.” Wikipedia, The Free Encyclopedia. Wikimedia
Foundation, Inc. http://en.wikipedia.org/wiki/Plasma_electrolytic_oxidation
38. Curran, J.A., T.W. Clyne. “Thermo-physical properties of plasma electrolytic
oxide coatings on aluminum” Surface & Coatings Technology 199 26 February
2005 Pp. 168-175.
39. Krishna, L. R., Purnima, A.S., Wasekar, N.P., et al. “Kinetics and Properties of
Micro Arc Oxidation Coatings Deposited on Commerical Al Alloys.”
Metallurgical and Materials Transactions A. Vol. 38A. February 2007. Pp. 370-
378.
40. Wilde, Anne. “Ceramic-Base Surface Treatment Technology for Light-Metal
Alloys.” Keronite Ltd., Cambridge, UK. February 9, 2005.
41. Rodgers, Kevin P., Heathcock, Christopher J. Controlled Casting of Al-Si
Hypereutectic Alloys. Comalco Aluminum Limited, Assignee. US Patent
5,316,070. May 31, 1994.
42. Kolbenschmidt Pierburg.“Latest machining techniques for aluminum cylinder
bores (Alusil® and Lokasil)” Press Release. Motor Service. www.ms-motor-
service.com
56
43. US Chrome Corporation. Technical Information: “Aluminum Engine Paper”
Copyright 2007. http://www.uschrome.com/aluminumenginepaper.html
44. “Wustite.” Wikipedia, The Free Encyclopedia. Wikimedia Foundation, Inc.
http://en.wikipedia.org/wiki/Wustite
45. Jacobs, James A., Kilduff, Thomas F. Engineering Materials Technology:
Structures, Processing, Properties, and Selection. 4th
Edition. Prentice Hall.
Upper Saddle River, New Jersey. Copyright 1985. Pp. 128, 523, 563.
46. Key to Metals: The World’s Most Comprehensive METALS Database. “Thermal
Spray Coatings: Part One.” Copyright 1999-2011. Website.
47. “Electroplating.” Wikipedia, The Free Encyclopedia. Wikimedia Foundation,
Inc. http://en.wikipedia.org/wiki/Electroplating
48. Dokuz Eyul University – Department of Metallurgical and Materials
Engineering. “PEO group: Plasma Electrolytic Oxide Coatings.” Website.
http://web.deu.edu.tr/triboloji/peogroup/peo.html
49. Askeland, Donald. The Science and Engineering of Materials. Monterey, CA:
Brooks/Cole. Copyright 1984.
50. Lim, C.S., Clegg, A.J. “The production and evaluation of metal-matrix composite
castings produced by a pressure-assisted investment casting process” Journal of
Materials Processing Technology. Volume 67, Issues 1-3. May 1997 Pp. 13-18
51. Barbezat, Gerard. “Thermal Spray Coatings for Tribological Applications in the
Automotive Industry” Advanced Engineering Materials. Volume 8, No. 7 2006
Pp. 678-681
52. Ford, Matthew, Fisher, Matthew. “Method for Coating Combustion Engine
Cylinders by Plasma Transferred Wire Arc Thermal Spray.” Paper. April 30,
2010.
53. Murakami. Diesel Engine Sulfuric Acid Corrosion Wear Analysis, Automotive
Engineering Society Theses, Vol. 26, No. 4 Pp. 45-50, 1995
54. American Foundry Society in Cooperation with GM Powertrain Casting
Development. “Aluminum Cylinder Block for General Motors Trucks/SUV
Engines.” Copyright 2004
57
55. “Group 12 – GM 4 Cylinder Engine 1.” Wikipedia, The Free Encyclopedia.
Wikimedia Foundation, Inc. Geometric & Intelligent Computing Laboratory.
Figure A1: Engine Block http://gicl.cs.drexel.edu/wiki/Group_12_-
_GM_4_Cylinder_Engine_1
56. Hirst, W. “Scuffing and It’s prevention.” Tribology Practical Reviews, I
Mechanical Engineer. Copyright 1975.
57. “Wear.” Wikipedia, The Free Encyclopedia. Wikimedia Foundation, Inc.
http://en.wikipedia.org/wiki/Wear