Novel In-Cylinder Wear Coatings for Improved High Output Military Diesel Engine Performance and Durability

Award Information
Agency: Department of Defense
Branch: Army
Contract: W56HZV-18-C-0104
Agency Tracking Number: A181-099-1256
Amount: $99,977.58
Phase: Phase I
Program: SBIR
Solicitation Topic Code: A18-099
Solicitation Number: 2018.1
Timeline
Solicitation Year: 2018
Award Year: 2018
Award Start Date (Proposal Award Date): 2018-07-19
Award End Date (Contract End Date): 2019-01-15
Small Business Information
525 University Loop, Suite 114, Rapid City, SD, 57701
DUNS: 078866768
HUBZone Owned: N
Woman Owned: N
Socially and Economically Disadvantaged: N
Principal Investigator
 Frank Kustas
 (605) 716-0082
 fmkustas.nci@gmail.com
Business Contact
 Gretchen Kustas
Phone: (605) 716-0082
Email: frigreeng@gmail.com
Research Institution
N/A
Abstract
Future U.S. Army vehicles will require engines with low heat rejection, high power density, lower-friction (15 % reduction), reduced fuel consumption (2-5% lower), and higher durability. Our team, NanoCoatings, Inc. (NCI) and Southwest Research Institute (SwRI), will down-select the most promising coating technologies and coating materials for both piston-rings and cylinder-liners. Our preliminary down-selection consists of a high TRL 7 PVD coating already demonstrated by SwRI in heavy-duty diesel engine testing, which will reduce development risks to the U.S. Army. NanoCoatings, Inc. has a similar deposition system to enable technology transfer of the SwRI coating. For the cylinder liners, NCI proposes a higher risk novel Plasma Electrolytic Deposition (PED) immersion coating technology to deposit stabilized zirconia with WS2 solid-lubricant nanoparticles. NanoCoatings has already demonstrated PED coating of steels with alumina and the PEO coversion of Zr-metal into zirconia. Consequently we have relevant experience with this approach to produce a low thermal-conductivity, thermal-barrier coatingcontaining solid-lubricantson cast-Fe liner material. Coatings will be characterized using SEM examinations for microstructure/composition, indentations for relative adhesion/toughness, nanoindentation for hardness and modulus, block-on-ring sliding wear tests and PLINT TE77 sliding wear tests of coated ring segments against liner segments in diesel engine lubricants.

* Information listed above is at the time of submission. *

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