Tribological Performance of a Composite Cold Spray for Coated Bores

The tribological performance of a thermal sprayed, mirror-like surface with localized protuberances was investigated through tribotests and computational simulation. A composite coating with a 410L steel matrix and M2 tool steel hard particles was applied by the cold spray process as a bore coating for combustion engines. The presence of protuberances promoted the quick formation of an antifriction tribofilm when tested with an SAE 0W-16 containing ZDDP and MoDTC, which significantly reduced the asperity friction in comparison to the conventional engine coated bores in reciprocating tribological tests. An in-house computational model using deterministic numerical methods was used for the mixed and hydrodynamic lubrication regime. Lubricant film thickness and friction were simulated for a piston ring versus the proposed coating. The computer simulations showed that the protuberances reduced the hydrodynamic friction by increasing the otherwise very thin oil film thickness of mirror-like surfaces. Although not intuitive, this result was caused by the reducing of the oil film shear rate.

Automated summary

The tribological performance of a thermal sprayed, mirror-like surface with localized protuberances was studied through experiments and computational simulations. The presence of protuberances promoted the quick formation of an antifriction tribofilm, reducing the asperity friction in reciprocating tribological tests. Computer simulations showed that the protuberances reduced hydrodynamic friction by increasing the oil film thickness and reducing the oil film shear rate.