NANOSLIDE technology reduces friction losses and is soon to be introduced in mass production
The twin-wire arc spraying technology is currently considered an extremely cost-efficient method for the coating of cylinder surfaces in combustion engines. In order to provide cost-effective integration of the technology into the production process whilst ensuring process dependability, Daimler AG is partnering with Gebr. Heller Maschinenfabrik GmbH based in Nürtingen.
In the automotive industry, lower fuel consumption and thus also CO2 emissions are mostly achieved in combination with weight reductions and engine downsizing. However, efficiency can also be increased by reducing friction losses. Daimler AG, for instance, is using a newly developed thermal spraying process, a twin-wire arc spraying technology meanwhile known as NANOSLIDE, for the coating of cylinder bore surfaces and aluminium crankcases of automobile engines. The technology uses a twin-wire arc spraying process to melt iron/carbon wires and spray them onto the cylinder surfaces of the lightweight aluminium crankcase with the help of a gas flow. Compared to other thermal coating processes, NANOSLIDE is considered extremely economical and technologically superior. However, the coating process requires optimal co-ordination of the quality-determining parameters such as current, voltage, wire feed and process gas flow. AMG's M156 V8 engine already demonstrated the high efficiency of the technology in 2005. Due to their thermally coated cylinder liners, the so-called LDS designed engines are superior in terms of displacement and torque, especially when compared with similar aspirated engines incorporating conventional lining technology. That is why the innovative technology has been used for all 6.3-litre AMG engines from 2006 onwards. In the context of the BlueEFFICIENCY measures the NANOSLIDE technology has been enhanced further for application in the V6 Diesel engines. NANOSLIDE reduces the engine weight by 4.3 kilogrammes compared to the preceding engine and provides additional fuel savings of 3 percent.
HELLER completes process chain with twin-wire arc spraying technology
The introduction of the NANOSLIDE technology in high-volume production requires market-oriented solutions in terms of system supply and services. To provide all this, Daimler AG has entered a partnership with Gebr. Heller Maschinenfabrik GmbH in Nürtingen. With a globally available portfolio of systems and services for the NANOSLIDE process chain, HELLER will soon provide a technical centre for the coating of customer-specific prototypes using NANOSLIDE technology.
Although the technology has only been used for exclusive low-volume series until now, the use in medium-volume production already provides significant competitive advantages compared to existing cylinder lining technologies. The technology already complies with the production rules and criteria of the automotive industry. From there, it is only a small step to high-volume production.