85
A Novel Process for the
Application and Finishing of Nanocrystalline Superhard Steel onto Internal
Combustion Engine Components--Faraday Technology, Inc., 35 Huls Drive,
Clayton, OH 45315-8983; 937-836-7749,
www.faradaytechnology.com
Mr. Alan Bonifas, Principal
Investigator, alanbonifas@faradayechnology.com
Dr. E. Jennings Taylor, Business
Official,
DOE Grant No. DE-FG02-03ER83655
Amount:
$99,925
This project will introduce nanocrystalline metals in the
form of coatings to improve the wear characteristics of internal combustion
engine (ICE) components, enabling higher operating temperatures and,
consequently, better fuel efficiency. Using
a novel electrophoretic deposition technique, a uniform nanocrystalline coating
will be placed on materials that are of interest to internal combustion engine
manufacturers. Then, using an
electrically-mediated finishing and machining process, the coatings will be
treated to provide the necessary surface finish and dimensional accuracy.
Phase 1 will: (1) deposit, via electrically-mediated electrophoretic
deposition, super hard steel coatings, (2) characterize the structural and
mechanical properties of the coatings, (3) evaluate the surface finish and
dimensional accuracy of the coating relative to thermal spray techniques, (4)
polish and machine the coating by adapting electrically-mediated techniques that
have been successfully implemented on other difficult-to-machine materials, and
(5) evaluate the combination of the above techniques in terms of implementation
cost and performance, as compared to currently practiced techniques.
Commercial Applications and Other Benefits as described by awardee: With the application of nanocrystalline coatings to ICE components, the improvement of friction and wear characteristics should be improved, increasing the fuel efficiency of the engine. Increased fuel efficiency would have major impacts, including reductions in waste energy, energy imports, air pollution, greenhouse gas emissions, and energy costs.