collaboration leveraging material development

© MAHLE

Collaboration leveraging

material development

André Ferrarese, September, 2016

MAHLE Metal Leve S.A.2

Collaboration leveraging material development

© MAHLE

Agenda

• MAHLE Group

• TriboFlex Consortium

• Case Coated Bore and Superlubricity

• Conclusions

MAHLE Metal Leve S.A. © MAHLE


MAHLE Group

3

MAHLE Metal Leve S.A. © MAHLE4


MAHLE Metal Leve


Developed and manufactured products

in more than 60 countries


© MAHLE

MAHLE Metal Leve S.A.

Technology Centers

6


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South America Tech Center - Jundiaí


Innovation Process


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Collaboration


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Tribo-Flex Overview


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Tribo-Flex - Overview


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Pre-Project:

Step 1

2015

(Step 5)

2014

(Step 4)

2013

(Step 3)

Agreements

(Step 2)

• “Kick-out” meetings

• Tribology challenges in

Flex-Fuel engines

• FAPESP/PITE, 2009-12

• Official agreements:

Companies-Universities-

FAPESP

• First MSc and PhD

students

• Definition of research

topics: - FL00: Tribological

characterization of flex-fuel

engine components;

- FL10: Tribology of piston-

rings-bore system;

- FL20: Tribology of

valve/valve seat;

- FL30: Modelling

- FL40: Training

SUMMITS

VTL – Virtual Tribo Laboratory

• 3 Tribology Courses

• 5 national and

international

conferences

• 2 journal papers

• Equipment: RAMAN,

SRV (Petrobras)

• 1 MSc


• 1 International

workshop

• 9 national and

international

conferences


• Cutoff (Isomet),

durometer, tribometer

UMT, etc

• 1 PhD, 1 MSc

SURFAT – Surface analysis,

folded metal, etc

SurfLUB –

Deterministic

simulation for

TLOCRs

• Valve/valve seat test

• 3 PhD, 1 MSc

• BAM, Nagel+Grob


• 4 International meetings

(Super-lubricity)

• 22 national and

international

conferences


LUBST –

Bearing

simulation

tools

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2 Main Outcomes (2009-15)


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Valve / Valve Seat

Engine Bearings

Piston-Ring Liner Contact

- Computational tools for

component (VTL) and

deterministic/roughness

(SurfLUB) scales simulations

- Advanced surface roughness

analysis (SURFAT), i.e.

folded metal quantification,

roughness filters etc.

- Studies on lubricant additives

and their behaviors in the

presence of ethanol

- Advanced modelling and

simulation framework for

bearings’ systems (LUBST)

- Effect of different lubricant

viscosity index improvers

(VIIs) on the conrod

performance of HSEs.

- Effect of body and conter-body

hardness, load, work hardening on

wear of valve materials

- Effect of temperature,

speed and load on wear

of valve materials

- Characterization of oxide

formation and growth mechanism

- Novel methodology for

valve/valves seat bench tests

(BAM interaction)


Softwares


© MAHLE13

http://www.lfs.usp.br/Portal_Triboflex/mahle.html

Summits

2D & 3D surface analysis, input for commercial (and in-

house) simulations (Excite, Ricardo, GT-Suite etc.)

LUBST – Lubrication Simulation Tools

Deterministic simulation for bearings and rings with

complex geometries and surfaces.

Deformation

Fluid pressure


International Symposia and Courses


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Int. workshop “Super-Lubricity in the

Automotive Real World” S. Paulo, May 2015

Academy

62%

Industry

38%

Abroad

15%

http://www.lfs.usp.br/superlubricity2015

1st Int. Course Liner honing

3 D evaluation, S. Paulo Oct 2013

Prof. Zlate Dimkowsky. Halmstad University

Academy

53%

Industry

47%


Tribology tests


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Ring & Liner Scuffing test

Based on the Daimler protocol

Lopez, D. et all at “VDI Symposium Zylinderlaufbahn,

Kolben, Pleuel, 2016, Baden-Baden

Figure 5: CoF during scuffing test and visual analysis after test

Time: 30 min to 15 h.

Temperature: room temperature to 500°C

Valve/Valve Seat – Friction-Wear test

Ball – Disk of SRV® Tribometer

Collaboration under discussion with


Partnerships


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Fully Deterministic Model for

Rings/Liners

(ICMC, USP, Buscaglia’s Group)

Costa, H.L. Impact of ethanol on the formation of antiwear

tribofilms from engine lubricants, Trib. Int. 93, 364-376 2016.

Effect of Ethanol on Lubricant

Tribofilms

(FURG, Imperial College London)

Prof. Henara Costa (FURG-RS)

Member of the IEA for Advanced Materials for

Transportation

Checo, H.M. et al., Moving textures - Simulation of a ring

sliding on a textured liner, Trib. Int. 72, 131-142 2016

http://www.lfs.usp.br/superlubricity2015


MSc and PhD related


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Bore Wear and deposits of engine tests

with E22 and E100

Dinécio Santos (GM)

Overview of the impact of biofuel ethanol

on the frictional response of piston

ring/cylinder liner contacts under cold-

start/warm-up/short-journey driving cycles

Prashan R. De Silva, Univ. Leeds/UK


Tribological Characterization of Flex-Fuel Engine

Components


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Identified oxides

Hematite (α-Fe2O3)

Magnetite (Fe3O4)

200 400 600 800 1000 1200 1400 16000

200

400

600

800

1000

1200350º C

Inte

nsi

ty (

A.U

.)

Raman shift (cm-1)

M -1

M -2

M -3

M -4

M -5

223

289

4041310

670

200 400 600 800 1000 1200 1400 16000

100

200

300

400

500

600

700Exhaust Valve

Inte

nsi

ty (

A.U

.)

Raman shift (cm-1)

M -1

M -2

M -3

223

289

404

1310

670


Research on Coated Bores

and Superlubricity at USP/LFS


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Dr. Eduardo Tomanik, Prof. Dr. A. Sinatora, Dr. F. Profito, Dr. T. Cousseau

Surface Phenomena Laboratory (LFS)

Department of Mechanical Engineering - University of Sao Paulo (USP)


Engine energy flow in the NEDC cycle


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From Schommers “Minimizing Friction in Combustion Engines”, MTZ 07-08 / 2013

Pay attention, on urban conditions:

• Friction loss is 9% of the fuel energy

but

• 25% fuel saving would be obtained

if Friction could be zeroed !



21

Coated bores

For decades, engine cylinder bores were made of honed Grey Cast Iron (GCI). Honingwas improved by experience with relative little theoretical basis.

Recently, coated bores have been introduced especially for Aluminium blocks. Oil micro-reservoirs are mostly due to surface pores rather than the honing grooves.

Coated bores bring challenges and opportunities for tribological improvements.

LFS is collaborating with Nagel and others to investigate coated bores, includingbenchmarking of one of the “state of art”, the Nissan Mirror like.

∆ Friction Losses (%)

Schutz, M. (Daimler) et al. MTZ 06/2013

typical coated bore topography.

Tokyo Autoshow 2014

Nissan Mirror like

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Pehnelt (Audi AG) et al. MTZ 04/2013 Rubach (VW AG) et al. MTZ 03/2014

Delta Friction Losses (%)

Schutz, M. (Daimler) et al. MTZ

06/2013J.M.BORDES (PSA) 2014

We are not trying to “re-invent the wheel” but paying attention for the worldwide “state of art”

Chen et al. (MIT) 2012

Cylinder

BoreTopography

measure

Topography

analysis

Modelling at

component

scale

Engine

Model

Hydro Pressure

Film Fraction (Cavitation)

Overview for Piston-Ring-Bore System Tribological Optimization

Plateau and slide

honing, coated

bores etc

Coated bores - R&D at LFS

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23

NISSAN Mirror-like (MLJ)

Mirror-like (MLN)

Slide Honing (SHN)

Slide with Deburring

(SHND)

Plateau Honing (GCI)

Coated bores - Topography

GCI SH SHD MLN MLJ

Notice the different height scale

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24

• Full-scale hydrodynamic and asperity contact simulations considering the 3D surface roughness.

• Link between local (roughness) and component size (engine) scales using the scaling proposed by Chen, 2011

(MIT) for the average curves.

Deterministic model

(LFS SurfLub)Engine model (Oil control ring)

(LFS VTL)

The mirror like variants reduced the OCR

friction – 10% in the 1000-3000 rpm range.

Coated bores

Engine Modelling

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25

Superlubricity, reducing friction to close to zero

J. M. Martin

(2015 SL Int. WS)

Fri

cti

on

www.crodalubricants.com

Erdemir, 2007

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“Superlubricity” in engines

Nissan has introduced superpolished ta-C engine components, mirror like coated bores, novel oils.

Renault is following the path and do not accept other than ta_C rings.

ITECH paper 32012046 (adapted from

Nissan)

Mirror like coated bore

(Ra < 0.1, Rk<0.2)

Tokyo autoshow 2014

26


© MAHLE


Conclusions


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• Material development is leverage from a more holistic approach on technical

field

• The holistic approach is related to more comprehensive understand trough

models about the technical phenomena

• Collaboration is key to leverage such developments

• Example of Tribo-Flex, a pre-competitive project, shows that high quality

work generates much other projects in different levels of knowledge and

technology.