Presented at the discussion panel "Materials Research and Innovation" - XV B-MRS Meeting - Campinas, SP, Brazil - September, 25 to 29, 2016.

1. © MAHLE
Collaboration leveraging
material development
André Ferrarese, September, 2016

2. MAHLE Metal Leve S.A.
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Collaboration leveraging material development
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Agenda
• MAHLE Group
• TriboFlex Consortium
• Case Coated Bore and Superlubricity
• Conclusions

3. MAHLE Metal Leve S.A. © MAHLE
Collaboration leveraging material development
MAHLE Group
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Collaboration leveraging material development
MAHLE Metal Leve

5. MAHLE Metal Leve S.A.
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Developed and manufactured products
in more than 60 countries
Collaboration leveraging material development
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Technology Centers
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Collaboration leveraging material development
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Collaboration leveraging material development
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South America Tech Center - Jundiaí

8. MAHLE Metal Leve S.A.
Innovation Process
Collaboration leveraging material development
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9. MAHLE Metal Leve S.A.
Collaboration
Collaboration leveraging material development
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10. MAHLE Metal Leve S.A.
Tribo-Flex Overview
Collaboration leveraging material development
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11. MAHLE Metal Leve S.A.
Tribo-Flex - Overview
Collaboration leveraging material development
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Pre-Project:
Step 1
2015
(Step 5)
2014
(Step 4)
2013
(Step 3)
Agreements
(Step 2)
• “Kick-out” meetings
• Tribology challenges in
Flex-Fuel engines
• FAPESP/PITE, 2009-12
• Official agreements:
Companies-Universities-
FAPESP
• First MSc and PhD
students
• Definition of research
topics:
- FL00: Tribological
characterization of flex-fuel
engine components;
- FL10: Tribology of piston-
rings-bore system;
- FL20: Tribology of
valve/valve seat;
- FL30: Modelling
- FL40: Training
SUMMITS
VTL – Virtual Tribo Laboratory
• 3 Tribology Courses
• 5 national and
international
conferences
• 2 journal papers
• Equipment: RAMAN,
SRV (Petrobras)
• 1 MSc
• 3 Tribology Courses
• 1 International
workshop
• 9 national and
international
conferences
• 4 journal papers
• Cutoff (Isomet),
durometer, tribometer
UMT, etc
• 1 PhD, 1 MSc
SURFAT – Surface analysis,
folded metal, etc
SurfLUB –
Deterministic
simulation for
TLOCRs
• Valve/valve seat test
• 3 PhD, 1 MSc
• BAM, Nagel+Grob
• 2 Tribology Courses
• 4 International meetings
(Super-lubricity)
• 22 national and
international
conferences
• 22 journal papers
LUBST –
Bearing
simulation
tools
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2 Main Outcomes (2009-15)
Collaboration leveraging material development
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Valve / Valve Seat
Engine Bearings
Piston-Ring Liner Contact
- Computational tools for
component (VTL) and
deterministic/roughness
(SurfLUB) scales simulations
- Advanced surface roughness
analysis (SURFAT), i.e.
folded metal quantification,
roughness filters etc.
- Studies on lubricant additives
and their behaviors in the
presence of ethanol
- Advanced modelling and
simulation framework for
bearings’ systems (LUBST)
- Effect of different lubricant
viscosity index improvers
(VIIs) on the conrod
performance of HSEs.
- Effect of body and conter-body
hardness, load, work hardening on
wear of valve materials
- Effect of temperature,
speed and load on wear
of valve materials
- Characterization of oxide
formation and growth mechanism
- Novel methodology for
valve/valves seat bench tests
(BAM interaction)

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Softwares
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http://www.lfs.usp.br/Portal_Triboflex/mahle.html
Summits
2D & 3D surface analysis, input for commercial (and in-
house) simulations (Excite, Ricardo, GT-Suite etc.)
LUBST – Lubrication Simulation Tools
Deterministic simulation for bearings and rings with
complex geometries and surfaces.
Deformation
Fluid pressure

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International Symposia and Courses
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Int. workshop “Super-Lubricity in the
Automotive Real World” S. Paulo, May 2015
Academy
62%
Industry
38%
Abroad
15%
http://www.lfs.usp.br/superlubricity2015
1st Int. Course Liner honing
3 D evaluation, S. Paulo Oct 2013
Prof. Zlate Dimkowsky. Halmstad University
Academy
53%
Industry
47%

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Tribology tests
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Ring & Liner Scuffing test
Based on the Daimler protocol
Lopez, D. et all at “VDI Symposium Zylinderlaufbahn,
Kolben, Pleuel, 2016, Baden-Baden
Figure 5: CoF during scuffing test and visual analysis after test
Time: 30 min to 15 h.
Temperature: room temperature to 500°C
Valve/Valve Seat – Friction-Wear test
Ball – Disk of SRV® Tribometer
Collaboration under discussion with

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Partnerships
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Fully Deterministic Model for
Rings/Liners
(ICMC, USP, Buscaglia’s Group)
Costa, H.L. Impact of ethanol on the formation of antiwear
tribofilms from engine lubricants, Trib. Int. 93, 364-376 2016.
Effect of Ethanol on Lubricant
Tribofilms
(FURG, Imperial College London)
Prof. Henara Costa (FURG-RS)
Member of the IEA for Advanced Materials for
Transportation
Checo, H.M. et al., Moving textures - Simulation of a ring
sliding on a textured liner, Trib. Int. 72, 131-142 2016
http://www.lfs.usp.br/superlubricity2015

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MSc and PhD related
Collaboration leveraging material development
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Bore Wear and deposits of engine tests
with E22 and E100
Dinécio Santos (GM)
Overview of the impact of biofuel ethanol
on the frictional response of piston
ring/cylinder liner contacts under cold-
start/warm-up/short-journey driving cycles
Prashan R. De Silva, Univ. Leeds/UK

18. MAHLE Metal Leve S.A.
Tribological Characterization of Flex-Fuel Engine
Components
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Identified oxides
Hematite (α-Fe2O3)
Magnetite (Fe3O4)
200 400 600 800 1000 1200 1400 1600
0
200
400
600
800
1000
1200
350º C
Intensity(A.U.)
Raman shift (cm-1)
M -1
M -2
M -3
M -4
M -5
223
289
404
1310
670
200 400 600 800 1000 1200 1400 1600
0
100
200
300
400
500
600
700
Exhaust Valve
Intensity(A.U.)
Raman shift (cm-1)
M -1
M -2
M -3
223
289
404
1310
670

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Research on Coated Bores
and Superlubricity at USP/LFS
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Dr. Eduardo Tomanik, Prof. Dr. A. Sinatora, Dr. F. Profito, Dr. T. Cousseau
Surface Phenomena Laboratory (LFS)
Department of Mechanical Engineering - University of Sao Paulo (USP)

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Engine energy flow in the NEDC cycle
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From Schommers “Minimizing Friction in Combustion Engines”, MTZ 07-08 / 2013
Pay attention, on urban conditions:
• Friction loss is 9% of the fuel energy
but
• 25% fuel saving would be obtained
if Friction could be zeroed !

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Collaboration leveraging material development
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Coated bores
 For decades, engine cylinder bores were made of honed Grey Cast Iron (GCI). Honing
was improved by experience with relative little theoretical basis.
 Recently, coated bores have been introduced especially for Aluminium blocks. Oil micro-
reservoirs are mostly due to surface pores rather than the honing grooves.
 Coated bores bring challenges and opportunities for tribological improvements.
 LFS is collaborating with Nagel and others to investigate coated bores, including
benchmarking of one of the “state of art”, the Nissan Mirror like.
∆ Friction Losses (%)
Schutz, M. (Daimler) et al. MTZ 06/2013
typical coated bore topography.
Tokyo Autoshow 2014
Nissan Mirror like
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Collaboration leveraging material development
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Pehnelt (Audi AG) et al. MTZ 04/2013 Rubach (VW AG) et al. MTZ 03/2014
Delta Friction Losses (%)
Schutz, M. (Daimler) et al. MTZ
06/2013
J.M.BORDES (PSA) 2014
We are not trying to “re-invent the wheel” but paying attention for the worldwide “state of art”
Chen et al. (MIT) 2012
Cylinder
Bore
Topography
measure
Topography
analysis
Modelling at
component
scale
Engine
Model
Hydro Pressure
Film Fraction (Cavitation)
Overview for Piston-Ring-Bore System Tribological Optimization
Plateau and slide
honing, coated
bores etc
Coated bores - R&D at LFS
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Collaboration leveraging material development
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NISSAN Mirror-like (MLJ)
Mirror-like (MLN)
Slide Honing (SHN)
Slide with Deburring
(SHND)
Plateau Honing (GCI)
Coated bores - Topography
GCI SH SHD MLN MLJ
Notice the different height scale
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Collaboration leveraging material development
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• Full-scale hydrodynamic and asperity contact simulations considering the 3D surface roughness.
• Link between local (roughness) and component size (engine) scales using the scaling proposed by Chen, 2011
(MIT) for the average curves.
Deterministic model
(LFS SurfLub)
Engine model (Oil control ring)
(LFS VTL)
The mirror like variants reduced the OCR
friction – 10% in the 1000-3000 rpm range.
Coated bores
Engine Modelling
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Collaboration leveraging material development
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Superlubricity, reducing friction to close to zero
J. M. Martin
(2015 SL Int. WS)
Friction
www.crodalubricants.com
Erdemir, 2007
© MAHLE

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“Superlubricity” in engines
Nissan has introduced superpolished ta-C engine
components, mirror like coated bores, novel oils.
Renault is following the path and do not accept other than
ta_C rings.
ITECH paper 32012046 (adapted from
Nissan)
Mirror like coated bore
(Ra < 0.1, Rk<0.2)
Tokyo autoshow 2014
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Collaboration leveraging material development
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27. MAHLE Metal Leve S.A.
Conclusions
Collaboration leveraging material development
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• Material development is leverage from a more holistic approach on technical
field
• The holistic approach is related to more comprehensive understand trough
models about the technical phenomena
• Collaboration is key to leverage such developments
• Example of Tribo-Flex, a pre-competitive project, shows that high quality
work generates much other projects in different levels of knowledge and
technology.

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Collaboration
to find the
right path