Materials & Advanced Manufacturing (M&AM) Adaptive Graphite Coatings Improve Fit and Function of Pistons, Turbos and Other Precision Devices Andrew Suman President, Line 2 Line, Inc. 4866 White Lake Rd. Clarkston, MI 8/10/2018 UNCLASSIFIED: Distribution Statement A. Approved for public release; distribution is unlimited
Materials & Advanced Improves Fit and Function Manufacturing (M&AM) Graphite Coatings polish themselves to a perfect fit, minimizing clearances, improving oil films & enhancing efficiency Graphite coatings are engine friendly and do not react with motor oils and transmission fluids Protects components from sand Reduces (Re)Manufacturing Costs – Cheap and easy to apply Improves Engine Efficiency 7% (Rubel -Cummins 14.7L diesel turbo) Extends Part Life 300% (Plutz -Rotax 500 top end life) Decreases Noise 50% (L2L – Shindiawa piston) Increases Idle Oil Pressure 100% (Riley – gerotor pump) 2
Adaptive Abradable Powder Materials & Advanced Manufacturing (M&AM) Coatings (AAPC’s) - Applications UNCLASSIFIED: Distribution Statement A. Approved for public release; distribution is unlimited 8/10/2018
Materials & Advanced AAPC Attributes Manufacturing (M&AM) • Unique patented process • Blend of plastics and solid lubricants that makes graphite stick to automotive parts • Thin or thick – 20 micron to 250 + micron • Coating hardness/texture/thickness tuned for applications • Self-fitting – via dry abrasion or lubricated Stribeck Fitting • Seats in quickly - lasts life of device • Improves performance, TBO, and life • Enhances manufacturability UNCLASSIFIED: Distribution Statement A. Approved for public release; distribution is unlimited 8/10/2018
Materials & Advanced AAPC Utilization Since 2000 Manufacturing (M&AM) • Over 16M automotive powertrain components • Commercial- ~45,000 pistons of all types, screw compressors, turbo housings, roots blowers, oil pumps, vacuum pumps, lifters, cams, bearings, vintage component restorations • Military – drone pistons, advanced engine development, air pumps 8/10/2018 UNCLASSIFIED: Distribution Statement A. Approved for public release; distribution is unlimited
Materials & Advanced AAPC’s – How They Work Manufacturing (M&AM) • Add coating to standard size or worn metal components • Coat thick enough to build it tight (light interference-OK) • Break-in during initial operation perfect fit and uniform loading between mating parts • Ideal geometry lasts – Minimize clearances 3D for efficiency – Reduces vibration, shock loads, oil film failures – Extends Time Before Overhaul (TBO) and Life 8/10/2018 UNCLASSIFIED: Distribution Statement A. Approved for public release; distribution is unlimited
Materials & Advanced AAPC Has Texture & Thickness Manufacturing (M&AM) • Texture aids break-in • Finds ideal component shape, topography supports oil film Magnifications After Break-In Prior to Break-In ~150X 8/10/2018 UNCLASSIFIED: Distribution Statement A. Approved for public release; distribution is unlimited
Materials & Advanced AAPC Topographic Advantage Manufacturing (M&AM) The image part with relationship ID rId2 was not found in the file. The image part with relationship ID rId2 was not found in the file. Thickness 6µm Thickness 41.6µm Burnished 165K Cycles Burnished 1,000K Cycles After Brk-In Ra 1.2µm Rz 7.8µm mr1 4.3% mr2 81.2% Ra 0.1µm Rz 0.7µm mr1 7.1% mr2 85.7% Thickness 47.8µm Thickness 19.7µm New New Ra 2.2µm Rz 13.3µm mr1 8.3% mr2 91.5% Ra 0.4µm Rz 2.7µm mr1 7.4% mr2 89.9um AAPC Thin Liquid SFL Reciprocating Wear Test 2.3” Stroke, 90 cycles per min, 425 psi load, 250 F, 5W30 Castrol 8/10/2018 UNCLASSIFIED: Distribution Statement A. Approved for public release; distribution is unlimited
Materials & Advanced Dry Application - Turbo Manufacturing (M&AM) • Zero Clearance • Zero Friction • Efficiency – Throttle Response and Fuel Economy • Protection • Restoration 8/10/2018 UNCLASSIFIED: Distribution Statement A. Approved for public release; distribution is unlimited
Materials & Advanced Turbo Field Data Manufacturing (M&AM) • AAPC Improved Borg-Warner – Special 88 mm Turbo efficiency 78 • Achieved boost @ 1K- 76 2K lower shaft speed 74 (red shifted left) 72 • Advantage compounds Boost (psi) 70 no coating 5-16 through each gear 68 no coating 6-6 • Further study required 66 no coating 6-16 64 coated 7-22 • Courtesy of 62 60 Kevin Kwiatkowski, 110000 115000 120000 125000 Shaft Speed (RPM) Kiggly Racing 8/10/2018 UNCLASSIFIED: Distribution Statement A. Approved for public release; distribution is unlimited
Materials & Advanced Turbo Field Data Manufacturing (M&AM) We were out again tonight chipping away at the FWD unibody record. Every time on this slip is a new personal best! The 60' is the new 28x10.5" tire FWD record. The car went in the trailer running great. We will give her a little maintenance and a good checkup, then send it at The Shootout! -Kevin Kwiatkowski, Kiggly Racing The image part with relationship ID rId3 was not found in the file. First AAPC Runs *Personal Best Times *60 Foot Record 8/10/2018 UNCLASSIFIED: Distribution Statement A. Approved for public release; distribution is unlimited
Materials & Advanced Turbo Case – Heavy Duty Manufacturing (M&AM) Holset HD Diesel Turbocharger • Rotor cuts perfect seal shape during operation • Improves fuel economy • Economical retrofit 8/10/2018 UNCLASSIFIED: Distribution Statement A. Approved for public release; distribution is unlimited
Materials & Advanced Lubricated Application- Pistons Manufacturing (M&AM) Improved Fit Improved Friction APC hones piston to the ideal fit Break-in event seeks minimum friction per Stribeck diagram for EACH bore Permanent geometric Creates uniform, stable oil film refinement across entire skirt Reduces secondary motions Enlarges contact area to spread load and lengthen oil leak path Improves ring flutter, seal and life Provides long term scuff resistance Reduces slap, noise, wear Tolerates foreign debris UNCLASSIFIED: Distribution Statement A. Approved for public release; distribution is unlimited 8/10/2018
Materials & Advanced STRIBECK FITTING with Lubricant Manufacturing (M&AM) 1. Build tight across entire skirt. At start-up, rapid, friendly wear-in. 2. Self fitting - Oil film forms and wear rate asymptotically declines O 3. Locked-in geometry - When there is just enough room for a stable oil film, the wear stops 4. APC Piston has: a) Minimized secondary motion b) Minimum oil film thickness for lowest friction c) No boundary lubrication Final shape is determined at temperature, under load. Friction, wear, and secondary motions of the rotating assembly are minimized. Engine efficiency and durability Surplus Oil are enhanced. TurbulenceLosses APC plateaus are polished, so a VERY THIN oil film can prevent asperity contact 14 8/10/2018 UNCLASSIFIED: Distribution Statement A. Approved for public release; distribution is unlimited
Materials & Advanced Uniform Contact Stress Manufacturing (M&AM) 8/10/2018 UNCLASSIFIED: Distribution Statement A. Approved for public release; distribution is unlimited
Materials & Advanced Stable Pistons Make More Power Manufacturing (M&AM) 8/10/2018 UNCLASSIFIED: Distribution Statement A. Approved for public release; distribution is unlimited
Materials & Advanced Stribeck Fitting = Less Vibration Manufacturing (M&AM) 8/10/2018 UNCLASSIFIED: Distribution Statement A. Approved for public release; distribution is unlimited
Materials & Advanced Stribeck Fitting = Less Noise Manufacturing (M&AM) UNCLASSIFIED: Distribution Statement A. Approved for public release; distribution is unlimited 8/10/2018
Materials & Advanced AAPC in Sandy Environments Manufacturing (M&AM) Refurbishing Protection This piston was restored • Particles embed or escape to optimum performance • No raised metal furrows • Core piston recoverable 8/10/2018 UNCLASSIFIED: Distribution Statement A. Approved for public release; distribution is unlimited
Materials & Advanced Conclusions/Recommendations Manufacturing (M&AM) • Since 2000, AAPC’s have been demonstrated to enhance performance and durability of precision devices. • AAPC has been technically and commercially successful in prototype, development, and automotive volumes. • AAPC’s have restored worn components (otherwise scrap) to better than new performance, TBO and life. • The US military branches could benefit from AAPC technology through improved readiness, performance, reduced sustainment costs, and longer life. • Validation on military equipment and AAPC military specifications are needed. 8/10/2018
Materials & Advanced Adaptive Graphite Coatings Improve Fit and Function Manufacturing (M&AM) of Pistons, Turbos and Other Precision Devices Thank You 8/10/2018
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