Company Miba Coating Group Speaker Eitzinger Günter Chief Engineer No powertrain without Miba Technology
Divisions at a Glance Miba 5000 Employees worldwide Bearing Group Sinter Group Friction Group New Technologie s Group Coating Group
Direct coating of conrods and bushings substitution of sliding bearings MIBA Coating Group
Friction losses example Daimler Source: Motorsymposium 2012 Vienna
Bearingless Conrod Direct coating Increased load ability Smaller bearings Less hydrodynamic friction Smaller tolerances Reduced Weight Increased stiffness Smaller engine Less oil consumption Smaller oil pump Example picture
Basic Technology e- Ar+ e- e- e- Cathode (ca. 600V) e- e- Miba Invention: The Cylindrical Cathode Advantage: Uniform Layer also for thick layers and large bearings Sputtering Process: 1. Argon Ions Bombard the Cathode 2. Al and Sn Atoms are released by the kinetic energy of the Ions 3. Freed Atoms are moving through the cylindrical space and form the layer of the bearing
Concept and Machinery Sputtering Coating 1 Ni Sputtering Coating 2 Loading Ion Etching Cleaning View into Coating Chamber Star Concept: Diameter: 30 190 Batch Concept: 190mm to 350 mm
Miba Sputter Bearing AlSnX 4 Description: AlSn20 layer applied using a Miba-developed PVD sputtering process 4 Application: High performance engines with high power density for high speed ferries, locomotives, ships and automotive applications 4 Characteristics: Extraordinary high load carrying capability, good tribological properties and superior wear resistance Roll bonded AlSn Sputtered AlSn
Hydro-dynamic Bearing Type Performance Kleinster Schmierspalt [µm] min oilfilm thickness [µm] 0.8 0.9 1 Bauarten / Bearing Types Prototype Standard Development Sputter NEW Application Area Sputter. Outstanding Hydrodynamic Performance 2 Application Area Tri-Metal. Synthetic OL PnSnCu PRO Rillenlager SnSb PRO Sputter Bearing 3 4 Tri-Metal Bearing BIAL AlSn25 AlSn20 BIAL AlSn20 AlSn40 Application Area Bi-Metal. 5 1000 1500 2000 2500 3000 3500 4000 4500 5000 5500 Schmierfilmspitzendruck [bar] max Oilfilm Pressure [bar]
Sputter Coating Properties New Al- based Alloy: Sn content ~20 wt. % Al - Matrix Alloy Composition: Sn 20 % Sputter - Layer Ni - Layer Bronze Cu 2 % Cross Section: Al 78 % Hardness: 80-120 HV References: Passenger Car: All European Common Rail Diesel Engines Heavy Duty Truck: DC, MAN, DAF High Speed: mtu, MWM - Deutz, CAT Medium Speed, GAS: GE - Jenbacher
Improved Sputtered Overlay Properties New Al- based Alloy: Sn content ~25 wt. % Near eutectic AlSi- matrix New Alloy Composition: Al 67,5% Sputter - Layer Ni - Layer Bronze Si 7,5% Sn 25,0% Production parameters: Ø Similar to AlSn20Cu Cross Section: Grain size: Sn < 1 µm Si << Sn Hardness: 130-150 HV
Relative Bearing Type Performance Best Overall Performance of all known Bearing Types Film Thickness Best Overall Performance in High Loaded Applications with Dirt Shock and Dirt Contamination 80 Fatigue Emergency 60 40 20 Bearing Types Sputter AlSnSi Sputter Std. Tri-Metal Test Results after 15 hours running time Dirt Contamination Test - - 100% Oil - Test runs without oilfilter 0 20 40 60 80 Cl - Corrosion 100 80 Wear Dirt volume Survival Rate [%] 60 40 20 Cavitation S - Corrosion 0 Trimetal Bearing 22 µm Overlay Trimetal Bearing 3 µm Overlay Rillenlager Sputtered Bearing 14 µm Overlay
Bearingless Conrod Direct coating 1. Layer 20-60 µm AlSn20Cu 2. Layer 5-20 µm Synthec Pro - Sliding Lacquer
Bearingless Conrod Direct coating Lemmon shape Compensate deformations Caused from masses of inertia
Taylor made Sputter Machines Capacity and Capability: Diameter Range 30 to 350 mm AlSn20, AlSn25 Si More than 50 Million coated bearings
Sliding lacquers: Synthec Pro Engine : EA 888 Audi 4 Cylinder Gasoline (World engine) Integrated Mass Balancer System Engine Start Stop reduced friction, improved emergency behavior of the system Rotational speed : max. 14000 rpm Max. Torque: max. 60 Nm One Radial- and two integrated axial bearings on a net shape sintered part
Detail Synthec Pro on Sintermaterial Typical structure of a 20 µm Synthec Pro overlay on a powdermetal part
Test arrangement Ring on disc tests SynthecPro (oil jar not shown) 100Cr6 Ring 1.2379 disc Ø40mm 58+2HRC coated, submerged in Shell Helix Ultra 5W30 Specific load 1-3-5MPa Temperature: 55 C
COF versus Load of Synthec Pro 100Cr6 ring against SynthecPro on 1.2379 hardened under Shell Helix Ultra 5W30@55 C cycles [1] 0 200.000 400.000 600.000 800.000 1.000.000 1.200.000 1.400.000 1.600.000 0,2 6 0,18 0,16 5 friction coefficient 0,14 0,12 0,1 0,08 0,06 0,04 0,02 4 3 2 1 specific load friction coefficient [-] specific load [MPa] 0 0 0 10000 20000 30000 40000 50000 60000 70000 80000 90000 sliding distance [m]
Synthec Pro on AlSi9Cu3 Alloy Cross-section from a 21 µm SynthecPro Layer on an aluminium alloy. Nearly all materials Possible.
Application examples of Synthec Pro sliding bearings split gears piston skirt sprockets bearing block intermediate gears
Synthec Pro Properties Performance Attributes Temperature range in applications (-50 up to 250 C) Superior wear behavior COF 0,03 0,08 (mixed friction area) Special adaptive behavior during running in time Due too solid lubricants extremely good emergency behavior Corrosion resistance Environmental friendly Potential for weight reduction Potential for cost reduction
Direct coating Substitution of bearings Advantages: Reduced weight Reduced space Smaller overall dimensions Smaller width or diameter Increased loadability Degreased friction losses also in hydrodynamic condition Enabler for use of low viscosity fluids >low friction Less tolerances Less assembly efforts
Contact Miba Coating Group Günter Eitzinger Head of Advanced Engineering Dr. Mitterbauer-Str. 3 A-4655 Vorchdorf, Austria T +43/7614/6541-8200 F+43/7614/6541-8400 M +43/664/8560418 www.miba.com guenter.eitzinger@miba.com