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October 2013

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New Cylinder Bore Coating

At Engine Expo North America 2013, Booth E308, HELLER Machine Tools, will display an innovative technology for coating cylinder bore surfaces of lightweight automotive aluminum engine crankcases. "The coating imparts a durable material, extends engine life and provides enhanced performance," said a company spokesperson.

"To date, lightweight motorblocks used cylinder liners, but there is now a practical alternative in twin-wire arc spraying, an extremely cost-effective technology for coating cylinder bores. Partnering with Daimler AG and other partners, Gebr. HELLER Maschinenfabrik GmbH, headquartered in Nürtingen, Germany, is tasked with industrializing all the steps of the process and developing the technology into a reliable process. It will be marketed globally under the name of HELLER CBC (CylinderBoreCoating.) Heller will also integrate the process into volume engine production," said a company spokesperson.

The twin-wire arc spraying process continuously melts iron/carbon wires and sprays them onto the cylinder bore surfaces of the lightweight aluminum crankcase with the help of a nitrogen gas flow.

"Compared to other thermal coating processes, the technology is considered cost-effective and technologically enhanced. Spray particle velocity is 60-80 m/s and spray particle temperature is up to 2,000°C," said the spokesperson.

"Besides the primary coating process, the CBC machining process at HELLER includes fine boring, roughening, finish honing to expose pores and finish machining. The process is all accomplished in a complete manufacturing system consisting of the innovative coating module, HELLER CBC 200 and the HELLER MC20 machining modules. Total cycle time, including part load/unload, for an 8-cylnder engine is five to six minutes. The engine blocks may be direct-loaded into the machining module or mounted on a swiveling exchanger," said the spokesperson.

"Although the technology has only been used for exclusive low-volume series until now, its application in medium-volume production already provides significant competitive advantages compared to existing cylinder lining technologies," said Vincent Trampus, HELLER VP of Sales. "The technology complies with the production rules and criteria of the automotive industry. Now, it is only a small step to mass production."

For more information contact:

HELLER Machine Tools

1225 Equity Drive

Troy, MI 48084


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