Remanufacturing of cylinder blocks by Ptwa thermal spray coating application

Abstract

The scope of this thesis is investigation of Plasma Transferred Wire Arc (PTWA) sprayed coating application on cylinder bore wall for remanufacturing purposes. 0.8% C- steel is used as coating material. According to literature survey, 0.8% C- steel is commonly used for cylinder block remanufacturing . However it hasn?t been used for remanufacturing of heavy duty engine cylinder block before. On the other hand, there is no experiment in local market as well. During the study, the effects of micro structure and mechanical properties of coating material on wear resistance, thus engine performance parameters are analyzed. The coating quality inclusing coating thickness, bond strength, porosity level and oxide content is investigated. 400 hours High Speed Test test was defined for the engines built coated blocks with 10W40 Castrol Oil. The reasons of selecting this test are ; a)Test data from previous test which had been performed with standard cylinder block was available for comparison, b) It is a recommended test to see wear of cylinder block and power conversion components including piston and rigs. According to test results, there was no coating delamination observed. The performance parameters of engine in view of power-torque, oil consumption and blow-by were in specification defined for the Ecotorq 9L engine