Honing&Coating

Product catalog summary

Introduction
Thermal spray coatings in cylinder bores of internal combustion engines are identified as high-performance materials for future applications. These coatings contribute to energy-efficient engines with reduced friction, shorter length, lower weight, and decreased production costs.

Process Chain Overview
The process chain for manufacturing cylinder bores includes mechanical roughing, PTWA (Plasma Transferred Wire Arc) coating, overspray jets, and honing. This chain significantly reduces friction, thereby lowering fuel and oil consumption, enhancing energy efficiency, reducing emissions, and increasing engine longevity.

Principles of Honing and Coating
Mechanical roughening is essential for achieving high adhesion during coating. It involves precision boring through cutting and forming processes. The PTWA coating uses a plasma light arc to melt and spray the supply wire onto the cylinder bore, resulting in a hard, wear-resistant, ductile, and easy-to-hone cylinder liner coating.

Overspray Jets and Honing
After thermal coating, overspray jets remove excess particles from casting surfaces below the coated cylinder bore using water jets, eliminating the need for expensive masking. The subsequent honing process, which involves multiple precision machining steps, creates a frictionless surface with high dimensional and form accuracy necessary for engine performance.

Conclusion
Gehring Technologies GmbH emphasizes its leadership in innovative technology and economic efficiency, supported by extensive experience and a global presence.

Catalog excerpts

Honing & Coating Thermal spray coats in cylinder bores of internal combustion engines are high-performance materials of the future. Energy efficient engines with low friction, reduced length and lower weight as well as lower production costs can be achieved due to the new process chain for the manufacture of cylinder bores. To this end, the process chain includes the following processes: to modern internal combustion engines with a high degree of energy efficiency, low emission and longevity is also made. Principles of honing and coating An overall result of this process chain is a marked reduction in friction, which considerably contributes to reducing fuel and oil consumption. Therefore a considerable contribution To achieve a high degree of adhesion when coating, mechanical roughening (pre-treatment) as a variant of precision boring is required. Mechanical roughening is realized through cutting processes and combined processes consisting of cutting and forming. The following PTWA coating (Plasma Transferred Wire Arc) works with a plasma light arc in which the supply wire is melted and then sprayed onto the cylinder bore. This results in a hard, wearresistant, ductile and easy to hone cylinder liner coating. Structure after honing Mechanical roughening - Mechanical roughing, PTWA coating, overspray jets and honing. The objective of honing and coating After the thermal coating follows the overspraying jets in which overspray particles are removed from the casting surfaces below the coated cylinder bore by means of a jets of water. Expensive masking is no longer required the process chain is thereby ready for production. The subsequent honing, a multiplestep precision machining process, creates the frictionless surface with a high degree of dimensional and form accuracy in the cylinder liner which is needed for the engine. Trust in the technology leader with many years‘ experience and global presence! Innovative technology combined with an economical mindset sets us apart. Gehring® Technologies GmbH • Gehringstrasse 28 • D-73760 Ostfildern Phone: +49 711/3405-0 • Fax: +49 711/3405-295 • [email protected] • www.gehring.de

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Honing&Coating

Honing&Coating

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