Positive Effect of Periodic Micropatterns on Compression Ring Friction

Internal combustion engines are increasingly regulated in regard to efficiency and environmental impact, which requires advanced optimization strategies of engine components. The contact between the top ring and the cylinder liner is critical to the efficiency of an internal combustion engine. As shown in a previous study, an amorphous carbon coating can greatly improve the friction properties of piston rings. This work expands on these results by fabricating laser-interference-induced microchannels on the coating perpendicular to the direction of movement with a mean depth of 0.97 and 3.13 mu m spatial period to further optimize the tribology. Fired single-cylinder engine measurements of the microtextured rings show a significant reduction in mean piston assembly friction of 5% for operation points that are relevant for urban transportation and up to 10% for specific operation points. Subsequent multibody elastohydrodynamic simulations prove that measured friction changes result from the compression ring microtexture. In particular, the microtexture increases the hydrodynamic pressure, reduces hydrodynamic losses, and leads to 20% lowered compression ring losses for an entire combustion cycle of the investigated operation point. In the future, such tribological concepts can be deployed in internal combustion engines that are powered by sustainable hydrogen or methanol.

Automated summary

Internal combustion engines are subject to increasing regulations on efficiency and environmental impact, necessitating advanced optimization strategies for engine components. Previous studies have shown that amorphous carbon coatings can significantly improve the friction properties of piston rings. This study further optimizes the tribology by fabricating microchannels on the coating using laser interference, resulting in a significant reduction in piston assembly friction. Subsequent simulations demonstrate that the friction changes are due to the compression ring microtexture, which increases hydrodynamic pressure and reduces losses.