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Engine Decks and Cylinder Heads

Corrosion and vibratory wear subject engine blocks and cylinder heads in mining equipment to severe stress and wear. With new Oerlikon Metco developments, they can be reliably coated and salvaged to prolong service life and meet the targeted performance.

Milling Instead of Grinding

Engine blocks and cylinder heads are the core of any mining equipment engine. But corrosion and vibratory wear degrades their surfaces, so that these components need to be machined periodically. During this process, parent material is removed, and the stacking height of the engine is changed and seals can be impaired. Components require thermal spray coatings to reclaim dimension, after applying new material over the required finish size dimension, the cylinders and decks must be machined to the final stack dimension.

To date, the most widely established process for this is electric arc wire spray (EAW). But together with the currently used materials (nickel- and ferrous-based alloys in combination with nickel-based bond coats), this results in relatively low coating adhesive and cohesive strengths, limiting the coating thickness capabilities. Ultimately, this means a higher likelihood of coating failure and shorter service life. Also, these materials are costly and must be ground.

In certain engines the cylinders cannot be EAW sprayed reliably to the required dimensions, due to difficult angles and high coating thickness requirements. So manufacturers use stainless steel inserts to repair corrosion — an additional challenge, as this can cause leakage and result in high repair costs.

Uncompromising adhesion solution — no matter the angle

Oerlikon Metco, as a full-service provider with application experts for EAW coatings, has developed a unique product portfolio of materials that are cost-effective solutions for coating engine decks and cylinders. New EAW processing equipment and materials produce coatings that meet the targeted performance. The new low-cost ferrous-based materials can be sprayed to high thicknesses of 5+ mm (0.2in) and more, if required, and exhibit high adhesive and cohesive strength. Additionally, the new materials can be sprayed at non-optimal spray angels from 45° to 90° without compromising adhesive strength, and they are designed to be easily machined using milling techniques.

Customers that applied Metco 8293 have been able to apply the coating at non-optimal angles and achieved higher coating thicknesses. They could shift to lower cost milling operations instead of grinding. Additionally, overall material cost are lower compared to the nickel-based alloys historically used.

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