Innovative coated piston from Federal-Mogul reduces fuel consumption and CO2
New EcoTough® -coated pistons reduce friction losses, improve wear resistance and can be introduced in volume production as a running change
Federal-Mogul Corporation, a leading global supplier of technologies that improve powertrain efficiency and enhance vehicle safety, has developed a new coated piston for gasoline engines that combines the properties of low wear and low friction in a single application. The new EcoTough®
-coated piston offers
superior wear resistance and reduces fuel consumption up to 0.8 percent, as well as reducing CO2
emissions, compared to
conventional piston coatings. The EcoTough-coated piston is compatible with existing and advanced cylinder bore finishes and can be introduced seamlessly in volume engine production as a running change.
The key behind EcoTough-coated piston technology is the composition of the coating, which is comprised of solid lubricants, including graphite, molybdenum disulphide (MoS2
) and
carbon fibre. In applications requiring additional protection, for example with a rough cylinder honing structure, the EcoTough-coated piston offers a greater coating thickness than pistons with conventional coatings. The technology suits high-volume manufacturing and is less sensitive to pre-treatment process variations, resulting in greater robustness and more consistent performance. The EcoTough-coated piston also fulfils the most stringent environmental standards and contains no toxic solvents.
“Federal-Mogul’s global strategy is to develop leading-edge technologies and innovative solutions that improve fuel economy, reduce emissions and enhance vehicle performance,” said Rainer Jueckstock, Federal-Mogul’s senior vice president of Powertrain Energy. “EcoTough is a proven solution that will help OEMs meet the stringent regulatory requirements for their vehicles.”
EcoTough-coated piston (right) shows visibly lower wear after testing at full load with 50 cold starts than the standard coated piston (left).
emissions
Customer and governmental mandates to reduce CO2
emissions and fuel Friction Coefficient comparison improvement
consumption make the reduction of parasitic friction losses between the piston and the cylinder bore a priority for vehicle manufacturers. At the same time, the power output per litre of engine displacement is increasing as engines are downsized and boosted by turbo- or super-charging, subjecting pistons to higher mechanical and thermal loads.
Reduction in parasitic losses
In laboratory testing, EcoTough-coated pistons show an 18 percent reduction in piston friction and an improvement of up to 3 percent in entire engine parasitic losses. Engine bench tests confirm a fuel economy benefit of 0.4 to 0.8 percent in normal driving conditions. In wear resistance testing at full load and after 50 cold-start cycles, EcoTough-coated pistons demonstrate a major reduction in wear on the piston surfaces in contact with the cylinder.
Fuel consumption improvement
“EcoTough offers vehicle manufacturers an attractive combination of benefits – a reduction in fuel consumption and CO2 emissions, coupled with improved wear resistance and straightforward implemen- tation,” said Dr. Frank Doernenburg, Federal-Mogul’s director of technology, pistons and pins. EcoTough-coated pistons have recently entered production for a high volume vehicle from a major European manufacturer.
LINK
www.federalmogul.com
Substantially reduced wear
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LUBE MAGAZINE No .99 OCTOBER 2010
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