Properties of Frictionally Coated Layer on Engine Bore
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A novel surfacing process is proposed for the inner bores of aluminium engines, which is the heaviest parts of automobile. This process is characterised by a plasticised coating with the use of frictional heat. The coating material is heated by frictional heat and plasticised by a rotating rod. The coating material is metallurgically bonded to the aluminium cylinder by plastic metal flow. Process advantages include no fusion of the substrate, little influence of heat, and sound coatings without any porosity and crack. Another advantage is the fine-grained structure of the coated material that results from the process. As conclusions, a novel process was developed to coat the inner surface of aluminium cylinders with fine-grained material with modified hardness. In the case of Al-Cu35% eutectic alloy coating, the maximum temperature reached 700 K. Higher rotational speed of core rod gave harder coating layers. This is attributed to the development of fine-grain structure on increasing the rotational speed. No defect was observed inside the coating layer as well as at the interface between substrate and coating. An actual engine cylinder was coated by this friction surfacing process. In the result, sound interface was obtained and the thickness of coating layer was uniform and thin.
IIW-Thesaurus keywordsFriction surfacing Surfacing Plastic deformation Deformation Engines Cylinders Al Cu alloys Aluminium alloys Light metals Al Si alloys Hardness tests Mechanical tests Thermal cycling Dye penetrant testing Nondestructive testing Ultrasonic testing Practical investigations
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