Study of the adhesion strength of sprayed coating used to repair cylinder faces

Today, there is insufficient study on the technology of repair of worn cylinder faces with the use of combined technology, including cold gas dynamic spraying (CGDS) of aluminum followed by microarc oxidation. In order to justify the possibility of using cold gas dynamic spraying to repair cylinder liners, the authors studied the shear strength of aluminum coating applied to cast iron sample by the CGDS method. The methodology and equipment for coating the cylinder face were developed. 10×30 cylinders made of BCh40 cast iron were used as samples. Aluminum powder of A-20-01 grade was sprayed on the DIMET-403 unit in modes “2-2”, “2-3”, “3-2”, “3-3”. The shear bond strength of the aluminum coating with cast iron was determined by pushing a sample (a cylinder with a sprayed belt coating) through a matrix. The results of strength tests have shown that heating mode “2” (about 300°C) achieves the highest shear adhesion strength compared to other modes. The maximum average strength of the coating was 11.99 MPa, which is 2.5 times less than when applying A-20-11 powder on steel. Under the “2-3” mode the required volume of material can be sprayed over less amount of time due to the higher powder feed rate. To ensure greater durability and reliability of the coating, the authors recommend spraying modes “2-2” and “2-3” with a powder flow rate of, respectively, 0.2 and 0.3 g/s. The developed technology produces relatively durable coatings for cylinder liner restoration. As a result, the study has revealed a possibility of restoring cylinders to nominal size and ensuring high wear resistance of their surface for any engine model.

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