efficiency and emissions optimisationof gears and …€¦ · rewitec gmbh target markets 20.11.19...
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REWITEC GmbH20.11.19
EFFICIENCY AND EMISSIONS OPTIMISATION OF GEARS AND ENGINES BY SILICON COATING
ENGINE EXPO 2018, REWITEC GMBH, STEFAN BILL, CEO
Efficiency and Emissions Optimization of Combustion Engines by Silicon Coating
Dipl.-Ing. Stefan Bill, Managing Director
REWITEC GmbHREWITEC GmbH
COMPANY AND PRODUCTSREWITEC®
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REWITEC GmbHREWITEC GmbH
• Establishment in 2003
• Developer, manufacturer and distributor of nano and micro particle based surfacerefinement products for the protection and the repair of tribological systems
• Patents Europe, China, USA
• World wide sales network
• Co-Founder and Managing Partner: Stefan Bill
• Acquisition by CRODA in 2019
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REWITEC GmbHREWITEC GmbH
Products
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REWITEC GmbHREWITEC GmbH
Target Markets
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WIND ENERGY- ONSHORE- OFFSHORE
INDUSTRY- STEEL- CEMENT- MINING- OIL, GAS
SHIPPING- MARINE- INLAND- YACHTS- SUBMARINE
AUTOMOTIVE- CONSUMER- OEM- MOTORCYCLES- RACING- OLDTIMER
REWITEC GmbH
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Higher Efficiency and longer Lifetime for engines withPowerShot®
Products W100
REWITEC GmbH
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Higher Efficiency and longer Lifetime for gearboxes withDuraGear®
Products W100
REWITEC GmbH
Products ChainSpray
Longer chain lifewith REWITEC®
ChainSprays
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REWITEC GmbHREWITEC GmbH
TECHNOLOGYREWITEC®
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REWITEC GmbH
Step 3New metal-ceramic surface
Original material properties will beimproved in terms of friction, temperature and wear significantly
Step 2Chemical reaction
The coating particles ceramize themetal surfaces in mixed friction zones
Step 1Chemical-physical process
The product uses the lubricant ascarrier to the mixed friction zones
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The coating process
REWITEC GmbHREWITEC GmbH
SCIENTIFIC TESTSREWITEC® IN ACTION
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REWITEC GmbH
2-Disc Assembly Rolling Wear Tests
Competence Center ofTribologyMannheim-Germany
Scientific tests
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Stress value: 1 GPa (normal force 2150 N)Rotating speed: 424 rpm / 339 rpm, slip 20 %Test-duration: 39,3 hTemperature: oil inlet temperature 60 °CFriction coefficient: µ=normal force/friction force
REWITEC GmbH20.11.19
Scientific tests2-Disc assembly rolling wear test
REWITEC GmbH
Scientific tests2-Disc assembly rolling wear test
VW first fill manual gearbox oil
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Steel disc treated without REWITEC® Steel disc treated with REWITEC®
(1 GPa; 424 rpm / 339 rpm, slip 20 %; 40 h; 60 °C)
REWITEC GmbH
• Red graph without REWITEC®
• Blue graph with REWITEC® added after 20 hours• Green graph with REWITEC® added at the beginning• Reduction of the surface roughness (Ra) due to wear up to 58 % • Reduction of the friction force up to 22 %
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Scientific tests2-Disc assembly rolling wear test –wind turbine oils
REWITEC GmbH
Rz, before = 2.97 µm Rz, after = 1.50 µm (- 49 %)Ra, before = 0.287 µm Ra, after = 0.186 µm (- 35 %)
Fuchs Pentosin EG FFL-7A with REWITEC® added after 20 h. (Friction reduction – 41 %)
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Scientific tests2-Disc assembly rolling wear test –Automotive gear oils
Rewitec® application
REWITEC GmbH
Rz, before = 2.57 µm Rz, after = 1.35 µm (- 47 %)Ra, before = 0.264 µm Ra, after = 0.158 µm (- 40 %)
DTM automotive gear oil with REWITEC® added after 20 h. (Friction reduction – 55 %)
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Scientific tests2-Disc assembly rolling wear test –Automotive gear oils
Rewitec® application
REWITEC GmbH
Oil analyses of the CASTROL X320
Freshoil sample CASTROL X320 Freshoil sample CASTROL X320 after REWITEC DuraGear W 100The following elements were foundadditionally in the tested oil after theapplication of the REWITEC DuraGear product:
- Si (Silicon up to 175ppm)- Al (Aluminium up to 138ppm)- Fe (Ferrum up to 6ppm)- K (Potassium up to 9 ppm)
These elements are a part of theREWITEC formulation. All the otherelements and additives in theoil are same concentration before and after the REWITEC DuraGear application.
REWITEC GmbH20.11.19
Scientific tests2-Disc assembly rolling wear test –steel vs. phosphated discs
2-Disc Assembly Rolling Wear Tests with VW first fill manual gearbox oils
Stress value: 1 GPa (normal force 2150 N)Rotating speed: 424 rpm / 339 rpm, slip 20 %Test-duration: 39,3 hTemperature: oil inlet temperature 60 °C
REWITEC GmbH
Scientific tests2-Disc assembly rolling wear test –steel vs. phosphated discs
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• Left: Standard steel disc• Right: Phosphated disc
StandardPhosphated
REWITEC GmbH
Scientific tests2-Disc assembly rolling wear test –steel vs. phosphated discs
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Standard steel disc without REWITEC® Phosphate disc withoutREWITEC®
REWITEC GmbH
Scientific tests2-Disc assembly rolling wear test –steel vs. phosphated discs
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Standard steel disc with REWITEC® Phosphated disc with REWITEC®
• Difference of the surface roughness up to 77 %
REWITEC GmbH20.11.19
• Reduction of the wear up to 9 %• Reduction of the friction force up to 28 %
Phosphated discwithout REWITEC®
Phosphated discwith REWITEC®
Scientific tests2-Disc assembly rolling wear test –steel vs. phosphated discs
REWITEC GmbH20.11.19
• Graph with REWITEC® steel-steel discs• Reduction of the friction force compared to phosphated discs:
51 % without REWITEC®
33 % with REWITEC®
VW G 052 527 A2 with REWITEC® added after 19 hours 39 minutes
Scientific tests2-Disc assembly rolling wear test –steel vs. phosphated discs
Rewitec® application
Standard steel discs
REWITEC GmbH
Test parameters:
Test specimens Test discs from previouslydamaged camshaft
Camshaft manufacturer German engine manufacturer
Test period 40 h
Lubricant Engine Oil SAE 10W-40 of the engine manufacturer
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Scientific tests2-Disc assembly rolling wear test –Engine oil
REWITEC GmbH20.11.19
Camshaft disc before testing withoutREWITEC® :• Large grooves
Camshaft disc after testing withoutREWITEC® :• Clearly visible grooves and micrograph• Light reduction of friction
after
before
Scientific tests2-Disc assembly rolling wear test –Engine oil
REWITEC GmbH
Camshaft disc before testingwith REWITEC® :• Heavy grooves in the right
section before the test-run
Camshaft disc after testing withREWITEC® :• Grinding pattern completely
disappeared• Grooves significantly reduced• Significant reduction of frictionafter
before
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Scientific tests2-Disc assembly rolling wear test –Engine oil
REWITEC GmbH
With REWITEC®
Without REWITEC®
• Upper graph without REWITEC®
• Lower graph with REWITEC®
• Reduction of the friction force up to 45 %• Reduction of the surface roughness up to 73 %*)*) 50% less surface roughness can lead to a 20-fold life expectancy– thesis of Dr.-Ing. Michael Gleß.
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Scientific tests2-Disc assembly rolling wear test –Engine oil
REWITEC GmbH20.11.19
Scientific testsPin-on-disk Tribometer
spring system
heater
ball attachment
sample
oil
electricmotor
thermal insulation
axial cylindrical roller bearings
Sliding
Rolling
disk ball
REWITEC GmbH
Measurement procedure:
I. Run-in of the contact until stableinterface conditions are established
II. Additive is added
III. “2nd Run-in”: improved tribo-contactis developed due to additive effects
IV. New stable interface conditions areestablished
V. Difference of friction levels beforeand after additiv addition:Reduction of friction due to additive
Additive is added
(schematic representation of typical measurement)
Decrease of friction due to additive
Initial run-in of contact
Stable interfaceconditions after
run-in
2nd run-inprocess
Figures shown laterfocus on this region
rela
tive
fric
tion
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Scientific testsPin-on-disc test
REWITEC GmbH20.11.19
Scientific testsPin-on-disc test – Honda Engine Oils
Following very low viscosity oils were tested with REWITEC®:
• Motor oil Honda Ultra Next:• 0W-8
• Motor oil Honda Ultra Green:• 0W-25
REWITEC GmbH20.11.19
Scientific testsPin-on-disc test – Honda Engine Oils
Honda Ultra Next motor oilRoom temperature; load 5 N; 4000 min-1
Friction reduction 30 % after 1 hour
REWITEC GmbH20.11.19
Scientific testsPin-on-disc test – Honda Engine Oils
Honda Ultra Green engineoilRoom temperature; load 5 N; 4000 min-1
friction reduction 35 % after 1 hour friction reduction 27 % after 1 hour
Honda Ultra Green engine oil70°C; load 5 N; 4000 min-1
REWITEC GmbH20.11.19
Scientific testsSealing Durability of Radial Shaft Seals
REWITEC GmbH20.11.19
Scientific testsSealing Durability of Radial Shaft Seals
Test 1: Engine oil (10W-40) without REWITEC® Test 2: Engine oil (10W-40) with REWITEC®
None of the test pairings showed significant signs of abrasion
REWITEC GmbH20.11.19
Scientific testsSealind Durability of Radial Shaft Seals
Test 1: Engine oil (10W-40) without REWITEC® Test 2: Engine oil (10W-40) with REWITEC®
None of the test pairings showed significant signs of abrasion
REWITEC GmbHREWITEC GmbH
EXAMPLES OF APPLICATIONWIND ENERGY | AUTOMOTIVE | MARINE | INDUSTRY
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REWITEC GmbH
• Gasoline and diesel engines• Gearboxes• Rear axles, differentials• Joints and shafts• Bearings of all kind• Drive chains
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Examples of application:Passenger cars, sports cars, bikes, oldtimers…
REWITEC GmbH20.11.19
Michael Krumm:
• German professional racing driver• Winner of the 2011 FIA GT1 World Championship• Mulitple participants of the 24 h of Le Mans, best finish 3rd• Brand ambassador for
Nissan-NISMO
REWITEC GmbH20.11.19
Examples of application:Nissan GT-R R32 engine treatment by M. Krumm
Test dynamometer:Dynapack Chassis Dynamometers Evolution 3000
Baseline: 281 BHP / 348 Nm
Treatment with REWITEC® PowerShot® L (29.01.2016)Improvement after 2 h: +16 BHP / 15 Nm
Additional transmission treatment with REWITEC® G5 (30.01.2016)
Complete end-result-improvement after 6 weeks: +28 BHP
REWITEC GmbH20.11.19
Examples of application:Nissan GT-R R32 engine treatment by M. Krumm
29.01.2016 17.03.201629.01.2016
REWITEC GmbH
Examples of application
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Application in Porsche Cayenne GTS:
All measurements performed in 4th gear, ratio 1.16 : 1
REWITEC GmbH
Measurement Date NEDC 90 km/h 110 km/h Particles Mileage
Consumption l/100 km l/100 km l/100 km g/km
First 30.05.2007 6,59 5,59 7,13 0,077 160,218
Second 13.06.2007 6,31 5,47 6,95 0,028 164,450
Reduction -4,2 % -2,2 % -2,5 % -63,6 %
Fachhochschule Frankfurt am Main, 15.06.2007
Examples of application
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Coating and analysis of a VW Touran :
REWITEC GmbH
Examples of application
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Toyota LandCruiser 1996 Diesel 4.2 L 24 valve 4 WD. From Vladivostok (Russia) to London & BackRewitec in engine, gearbox and differantials
REWITEC GmbH
Examples of application
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Application in a new truck Peterbilt 579:
REWITEC GmbHREWITEC GmbH
SENTIENT SCIENCEREWITEC® LIFETIME CALCULATIONS
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REWITEC GmbH
DigitalCloneMaterials-Based Computional Testing
Sentient Science
LIFETIME CALCULATIONS
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Analysis of REWITEC® DuraGear®
W100 Lifetime Effecton GE 1.5 MW Winergy 4410.2 Gearbox
REWITEC GmbH20.11.19
Mixed-EHL
Right: Surface pressureof two smooth surfacesinteracting withREWITEC®
Mixed-EHL Solution for Life Prediction
Left: Surface pressure of two rough surfacesinteracting withoutREWITEC®
REWITEC GmbH20.11.19
Sentient Science
LIFETIME CALCULATIONS
REWITEC GmbHREWITEC GmbH
CONCLUSIONAT A GLANCE
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REWITEC GmbH
Conclusion
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• Friction reduction• Wear reduction• Roughness reduction• Temperature reduction
Ø Higher efficiencyØ Longer lifetimeØ Higher reliability
REWITEC GmbHREWITEC GmbH
FOR YOUR ATTENTION
Many thanks
20.11.19
REWITEC GmbH
REWITEC GmbH
Dr.-Hans-Wilhelmi-Weg 1
35633 Lahnau, Deutschland
Telefon: +49 (0) 6441 / 445 99-0E-Mail: [email protected]
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