Many industries use coatings to extend product life, increase performance and reduce production and maintenance costs. The Plasma Transferred Wire Arc (PTWA) Thermal Spray Coating process involves continuously melting a material in wire form and propelling it towards a substrate using a stream of gas or air to deposit it, creating a surface structure. The coating material may consist of a single constituent but is often an alloy or composite which can impart unique physical properties to the substrate surface that are only achievable through thermal spray processes. Other uses of thermal spray coatings include weight reduction, wear resistance, friction reduction, restoring dimensionality and modifying thermal or electrical properties.

The patented invention is a method and apparatus to thermally spray a coating onto the interior of a cylindrical surface. This process uses a solid or cored wire, which is cheaper and easier to handle than powder. Potential applications of the PTWA process include valve seats, cylinder head gaskets, cylinder head chambers, piston domes, flywheels wear surfaces and valve train components. The technology is proven and available today. There are over 2.7 million miles on the thermal spray fleet with no coating failures.

 

Benefits Summary

Applying a PTWA coating to cylinder bores of a cast aluminum engine improves the wear resistance of the bore and rings and improves scuff resistance due to the nature of the coating. The coating process eliminates the need for inserting cast iron liners or the use of high silicon content aluminum for linerless applications. The thermally sprayed coatings can be applied in relatively thin thicknesses, i.e., 100 – 1000 micrometers (0.1 – 1.0 mm or 0.004 – 0.040 inches). Use of the PTWA process can promote material flexibility through engineered surfaces, reduce costs and increase product flexibility while meeting performance needs.

Licensing Opportunity

Key non-automotive engine manufacturers are being offered the right to license this technology. Please contact either of the individuals listed below for more information or a demonstration.