Wear Model Investigating the Effect of Abradable Powder Coated Pistons on Engine Cylinder-Kit Performance

Surface coatings are one of the most widely used routes to enhance the tribological properties of cylinder kits due to effective sealing capability with low friction coefficient, high wear resistance, and low-cost. In the current study, we have conducted the characterization of the coatings on piston skirt and development of a wear model to explore the impact of abradable powder-coated (APC) piston skirts on piston rings. The underlying physical and mechanical properties, plus surface topology of the selected piston coating materials, are characterized at discrete depths moving from the top towards the substrate. The calibrated wear model is used to compare the APC coated piston and uncoated piston. The model depicts the benefits of APC in terms of the areas of hydrodynamic versus boundary lubrication of skirt and rings, wear, blow-by, reverse blow-by, and oil consumption. The goal is to explore the properties of the APC and link them to the performance of operating cylinder-kits.