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Otomotiv Parçalarına DLC Uygulama
Otomotiv Parçalarına DLC Uygulama
Otomotiv Parçalarına DLC Uygulama
ISSN 1881-2198
DOI 10.2474/trol.9.135
Review
( Manuscript received 7 May 2014; accepted 31 July 2014; published 30 September 2014 )
The application of DLC coatings in the automotive industry has increased significantly both in terms of
production volume and the kinds of applications involved. However, elucidation of the fundamental evaluation
and mechanism of friction and wear properties for DLC coating are still far from sufficient level. This article
discusses recent topics concerning the application of DLC coatings to automotive engine components and the
related research for tribological issues of DLC coating. For the application to engine components, several
typical examples are described. As an advanced one, the ta-C coated piston ring which has been applied
recently to both the compression ring and the oil ring of a new mass-produced inline 3-cylinder compact
gasoline engine is shown. The ta-C coated piston ring can reduce engine friction substantially compared with
the conventional Cr plating ring. Additionally, the a-C:H coated aluminum piston which can be accomplished
by shot-peening aluminum alloy substrate with fine tungsten particles shows exellent wear resistance. For
the research, three issues of the super-low friction, the evaluation of adhesion strength and wear resistance and
the rolling fatigue are discussed.
Keywords: diamond-like carbon, engine component, valve lifter, piston ring, piston, friction, wear resistance,
engine application, a-C:H, ta-C
6000 Leaman
shock
Working Tools” and “Application of DLC Coating to 15th Sep.
Sliding Parts in Engine” were reported. In the first topic, 5000
it was described that the word of DLC was not
established as an academic term. Additionally, it is found 4000
obtain sufficiently due to the thin film about 1 micron K, which means no additional surface finishing is needed.
thickness made of carbon element mainly with the For the application to the front fork of motorcycles, an
amorphous construction. The other one is difficulty of amorphous hydrogenated carbon (a-C:H) coating was
detecting very thin tribochemical-reacted film adsorbed applied to the steel inner tube of the fork to reduce
on the sliding track directly by conducting surface friction [3]. This friction reduction helps to give the rider
analysis. an excellent driving feel. This coating technology has
This article discusses recent topics concerning the also been applied to the sliding members of the
application of DLC coatings to automotive engine suspension system on luxury vehicles.
components and the research for DLC tribology. Next, we will look at several applications to engine
components. For the fuel injection systems of automotive
2. Application to automotive engine components engines, DLC coatings have been applied to several
components such as the plunger of high-pressure diesel
Typical examples of automotive components coated fuel pumps. Because the sliding conditions of the fuel
with DLC coatings are shown in Table 1. In this last injector and other pump sliding parts have become
decade, applications have increased markedly both in
severer due to higher contact pressure, several types of
terms of production volume and variety. First, we will DLC coatings were evaluated for the purpose of
look at some applications other than engine components. obtaining higher wear resistance under boundary
For the coupling clutch application, an amorphous
lubrication in the fuel [4]. The engine valve lifter is the
Si-doped hydrogenated carbon (a-C:H:Si) coating was most successful application of DLC coatings to a
applied to the steel plate that slides against the friction mass-produced component because a fuel-saving effect
plate in the torque control system used on 4WD SUVs.
is clearly obtained by reducing friction. The shape of the
The high wear resistance and high friction coefficient of valve lifter is adjusted to obtain stable coating quality
the a-C:H:Si coating resulted in a compact clutch system. because the lifter surface to be coated is flat. A
Additionally, the fact that the friction coefficient of this tetrahedral amorphous carbon (ta-C) coating, deposited
coating has a positive slope relative to increasing sliding by an arc ion plating physical vapor deposition (PVD)
velocity provides higher shudder resistance [2]. For the
method, has been applied to the valve lifters and piston
SUV differential gear application, a tungsten carbide rings of mass-produced gasoline engines (Fig. 2) to
doped amorphous hydrocarbon (WC/a-C:H) coating was improve fuel economy by a few percent. This ta-C
applied to the gear teeth to improve wear resistance. DLC
coating has been applied recently to both the
coatings can increase the life of gears by suppressing compression ring and the oil ring of a new
scuffing wear or spalling wear. In gear applications, it is mass-produced inline 3-cylinder compact gasoline
easy to coat a DLC film directly on the gear teeth as a
engine [5]. Friction force, indicated as the distance
measure for improving wear resistance because the film between the positive and negative values, was evaluated
is very thin, around 1 micrometer in thickness, and the in an engine firing test using a single-cylinder gasoline
temperature in the coating process is very low, below 473
engine lubricated with standard gasoline engine oil, as
Japanese Society of Tribologists (http://www.tribology.jp/) Tribology Online, Vol. 9, No. 3 (2014) / 136
Diamond-Like Carbon Coating Applied to Automotive Engine Components
Japanese Society of Tribologists (http://www.tribology.jp/) Tribology Online, Vol. 9, No. 3 (2014) / 137
Makoto Kano
Severe
scuffing
tests were conducted to evaluate the effect of one simple containing 1 mass% of ester (PAO+GMO) showed an
modifier on the friction properties of DLC coatings. ultra-low friction coefficient of 0.02, whereas an a-C:H
Typical DLC coatings selected for evaluation in this way coating/steel pair displayed a much higher friction
included hydrogenated amorphous carbon (a-C:H) and coefficient of 0.09 and that of a steel/steel pair was 0.100,
hydrogen-free tetrahedral amorphous carbon (ta-C). as shown in Fig. 6 [19,20].
Sliding tests were conducted at high Hertzian pressure of Friction properties of DLC coating pairs lubricated
700 Mpa under oil lubrication at a temperature of 353 K. with PAO+GMO at a temperature of 353 K were also
The effect of various friction modifier additives on the evaluated in SRV tests to make clear the reason for
friction properties of these DLC coatings was evalauted ultra-low friction. Figure 7 shows the friction
when used with a poly-alpha-olefin (PAO) based oil. coefficients obtained for different kinds of material
Many types of friction modifier additives were examined, combinations lubricated with PAO+GMO and pure
including amine, amide and ester (GMO). It was found glycerin [21]. Amazing results were obtained for the
that a ta-C coating/steel pair lubricated with a PAO oil ta-C/ta-C coating combination. The friction coefficients
of the ta-C pairs were substantially lower than those of
the a-C:H ones. These results strongly suggest that
ultra-low friction was obtained by the interaction
between the ta-C coating and the ester-containing oil;
0.140
0.120
Friction coefficient
0.100 80%
reduction
0.080 Break
Break through
through
0.060
0.040
0.020
0.000
Japanese Society of Tribologists (http://www.tribology.jp/) Tribology Online, Vol. 9, No. 3 (2014) / 138
Diamond-Like Carbon Coating Applied to Automotive Engine Components
0,2
PAO+GMO SRV tribometer
0,18 Glycerol SRV tribometer
0,16
0,14
Friction coefficient
0,12
0,1
0,08
0,06
0,04
0,02
Unmeasurable
0
steel/steel a-C:H/a-C:H ta-C/ta-C
Fig. 7 Super-low friction of self-mated ta-C under gradually to a final level of 0.085. That of the a-C:H pair
glycerol lubrication [21] (a-C:H/a-C:H) decreased from 0.08 to 0.045 for 1200
seconds and then stayed at a stable level. That of the ta-C
pair (ta-C/ta-C) decreased continuously from a high level
this property is attributable to the formation of a very thin, of 0.09 to 0.045. In contrast, that of the ta-C (T) pair
low-shear-strength tribofilm on the ta-C sliding surface (ta-C(T)/ta-C(T)) decreased from a very low level of 0.02
and a better lubrication condition. Moreover, super-low to a super-low friction regime below 0.01 in a very short
friction and zero-wear behaviour was notably obtained time and stayed at a very low level of 0.015 for 1800
for the ta-C/ta-C coating combination lubricated with seconds. The ta-C (T) coated by the T-shaped filtered arc
pure glycerin at 353 K. As shown in Fig. 7, the friction deposition method (Fig. 9) had very smooth surface
coefficient was below 0.01 and was actually not without lots of droplets [25]. The steel pair showed an
measurable with the equipment used. Moreover, the wear ultra-low friction coefficient initially, which was
scar was not visible when viewed under an optical probably due to the tribochemical reaction with oleic
microscope. This result suggests that superlubricity is acid. The friction coefficient then increased gradually
related to an alcohol chemical function (OH), which is above 0.08 due to increasing surface roughness caused
common to both GMO and glycerol molecules. by wear. For the DLC pairs, the ta-C pair showed a much
Further fundamental research on an optimum larger friction coefficient reduction than the a-C:H pair.
material combination of a DLC coating and a simple The higher friction coefficient especially in the initial
lubricant for reducing friction to super-low level was period for the ta-C pair was presumably caused by the
reported [22-24]. The Pin-on-disc reciprocating sliding larger surface roughness due to the presence of many
test under oleic acid lubrication was conducted at droplets compared with that of the ta-C (T) pair.
ambient temperature. Friction curves with greatly Therefore, the effect of the ta-C pair on reducing friction
different shapes were observed for sliding times from 0 was probably comparable to that of the ta-C (T) pair. Of
to 30 minutes as shown in Fig. 8. The friction coefficient course, the mechanism of the super-low friction
of the AISI 52100 steel pair (steel/steel) was at a very properties of these DLC coatings must be made clear
low level of 0.02 for 300 seconds and then increased [26,27], but it will take a long time to obtain definitive
evidence due to the difficulty of conducting surface
analyses. It can be concluded that DLC coatings have an
0 .1 exceptionally high potential to provide super-low friction
0 .0 9
SUJ2/SUJ2 properties in combination with environmentally friendly
0 .0 8
fluids such as oleic acid lubrication.
Coefficient of Friction
0 .0 7
0 .0 6 ta-C/ta-C 3.2. Research for evaluation of adhesion strength and
0 .0 5 wear resistance
0 .0 4
a-C:H/a-C:H
The test method for evaluating the adhesion strength
0 .0 3 and wear resistance of DLC coating is described shortly.
0 .0 2 ta-C(Filter)/ Conventional test methods for evaluating the adhesion
ta-C(Filter)
0 .0 1 strength of DLC coatings include the Rockwell hardness
0
test for measuring material hardness[28,29] and the
0 600 1200 1800
Time , s
scratch test procedure for scratching coatings with a
diamond-tipped indenter[30-32]. These test methods
Fig. 8 Super low friction of self-mated ta-C under push an indenter into the coating or drag it along the
oleic acid lubrication [24] surface while applying downward pressure on the device,
Japanese Society of Tribologists (http://www.tribology.jp/) Tribology Online, Vol. 9, No. 3 (2014) / 139
Makoto Kano
Japanese Society of Tribologists (http://www.tribology.jp/) Tribology Online, Vol. 9, No. 3 (2014) / 140
Diamond-Like Carbon Coating Applied to Automotive Engine Components
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