Overview of automotive engine friction and reduction trends–Effects of surface, material, and lubricant-additive technologies

Abstract

Abstract:The increasing global environmental awareness, evidenced by recent worldwide calls for control of climate change and greenhouse emissions, has placed significant new technical mandates for automotives to improve engine efficiency, which is directly related to the production of carbon dioxide, a major greenhouse gas. Reduction of parasitic losses of the vehicle, powertrain and the engine systems is a key component of energy conservation. For engine efficiency improvement, various approaches include improvements in advanced combustion systems, component system design and handling-such as down-sizing, boosting, and electrification-as well as waste heat recovery systems etc. Among these approaches, engine friction reduction is a key and relatively cost-effective approach, which has been receiving significant attention from tribologists and lubricant-lubrication engineers alike. In this paper, the fundamentals of friction specific to the environments of engine components tribology are reviewed, together with discussions on the impact of developing vehicle powertrain technologies, surface and material technologies, as well as lubricant and additive technologies on promises of continuing friction and wear reduction trends. The international accords on climate change require further gains in fuel efficiency and energy sustainability from all industry sectors including those in the automotive and the broader internal combustion engine industries, and the latter encompass off-highway, power generation, marine, and rail industries as well. This paper focsuses on friction reduction in mainly automotive engines, however.The paper starts with a clarification of the common descriptors of mechanical losses and friction in the engine, followed by the topic of lubrication fundamentals such as lubrication regimes. Then the lubrication of the contacting surfaces in each of the major engine subsystems is discussed in turn. These subsystems include the piston assembly: ring-pack/liner, piston-skirt/liner, and piston-pin/connecting-rod contacts; connecting rod and crankshaft bearings; and the valvetrain subsystem. The relative contributions to total friction from the various subsystems are discussed, with the piston-assembly contributing to about half of the total friction. The remainder of the friction comes from the crankshaft, connecting rod, camshaft bearings, and the valvetrain oscillating parts. The bearings are in predominantly hydrodynamic lubrication, in contrast to the valvetrain oscillating components, which are characterized to be mostly in the mixed/boundary lubrication regimes.Despite the title of the paper, a section on emerging powertrain technologies-including that of combustion in gasoline and diesel engines-is also given in the context of the trend towards clean and efficient propulsion systems. The impact of these developing technologies on the reduction of friction and parasitic losses via component, material, and lubricant deisgn will be discussed. These technologies include gasoline direct injection (GD...

Design and application of friction pair surface modification coating for remanufacturing

“…Further, the surface accuracy and dimension tolerance requirements of the friction pairs are very strict. Serious accidents, starting difficulty, and power failure may occur if the main components of the engine suffer serious damage like scuffing, adhesion, and fatigue spalling [4]. Reliable lubrication is important to address the above friction failure problems.…”

Design approach for optimization of a piston ring profile considering mixed lubrication

“…(14), the higher FMEP is, except for n = 5. When n  [1,5], a lower FMEP can be achieved. In addition, F a accounts for about 80% of F t .…”

“…The tribological behavior of these tribosystems has a substantial influence on engine friction power loss, fuel consumption, harmful emissions, and effective gas sealing. It has been estimated that about 20 to 30 percent of an engine's mechanical power loss is caused by the friction loss in the ring/liner tribosystem [1,2]. A good lubrication state in the ring/liner interface is vital for reducing engine friction and improving engine performance [3,4].…”

Low Friction and High Solid-Solid Contact Ratio—A Contradiction for Laser-Patterned Surfaces?

“…Friction, wear and lubrication play a significant role in numerous daily applications and can be directly related to the energy efficiency of those applications and components [1][2][3]. Applications range from passenger cars to aircrafts over wind turbines or heavy vehicles in the mining industry.…”