Engineering research of DLC coating in piston pins and bucket tappets

Purpose The purpose of this paper is to study the engineering application of diamond like carbon (DLC) coatings on the surfaces of piston pins and bucket tappets for a 2.0 L supercharged gasoline engine. The friction loss and durability of DLC-coated components were investigated. Design/methodology/approach The tribological characteristics were examined under oil-lubricated conditions in a CETR UMT reciprocating tribometer. In a motored engine test rig, friction loss torque test was performed to estimate the improvement in fuel economy. Fired engine durability bench tests of typical duration of 450 h were completed to access the durability and wear resistance of DLC coating. Before and after durability tests, coated and uncoated components were measured on the sliding surface by a profilometer technique. Findings Friction and wear test results show that DLC coating has low friction coefficient and reduces the wear rates by almost ten times compared to those of uncoated surfaces. Friction loss measurements indicate that DLC-coated tappets can reduce valve train friction loss by 29 per cent, and DLC-coated piston pins can reduce piston group friction by 11 per cent. Based on fired engine durability bench tests, it is evidenced that none of the coated tappets and pins show any noticeable peeling or delamination. Wear profiles analysis results indicate that DLC-coated engine components give rise to a substantial reduction in wear. Originality/value DLC coating applied onto the working surface of piston pin and bucket tappet can effectively reduce the friction loss of gasoline engine. DLC coating exhibits sufficient durability and improves friction and wear performance.