[DeTomaso] whats old is new again
Guido deTomaso
guido_detomaso at prodigy.net
Sat Dec 5 16:03:00 EST 2015
Unsleeved aluminum motorcycle cylinders can be re-plated by third party vendors, though I have no direct experience with that.
Be interesting to see if the process described below will eventually compete with ordinary sleeving of an iron block.
GD
From: Larry - Ohio Time <Larry at ohiotimecorp.com>
To: detomaso at poca.com
Sent: Friday, December 4, 2015 9:01 AM
Subject: [DeTomaso] whats old is new again
When an engine fails or becomes very worn, it is usually pulled from
the vehicle and scrapped. Ford wants to change that by utilizing a
high-tech plasma process to remanufacture broken engines. The process
reduces carbon emissions by about half when compared to making a new
engine to replace the old one, and results in a like-new engine block.
. [1]When an engine fails or becomes very
worn, it is usually pulled from the vehicle and ...
. [2]When witnessed first-hand, the plasma
coating process looks similar to spray painting, but with a bright ...
. [3]The process for Ford involves taking
worn, high-mileage engines and using plasma coatings to refurbish and
...
. [4]The process being used was originally
developed for engine performance enhancement
The goal is to extend the performance of a vehicle by lengthening its
lifespan, thus reducing its overall environmental footprint. It ties in
with other research being done by Ford to include [5]vegetable fibers
in plastics and soy fibers in foam and cloth.
The process was originally developed for engine performance
enhancement, says Juergen Wesemann, manager of Vehicle Technologies and
Materials, Ford Research and Advanced Engineering. The Plasma
Transferred Wired Arc (PTWA) thermal spray process applies a coat to an
engine block which helps bring it back to original condition. This
removes the need for additional heavy parts.
[6][cid:image005.jpg at 01D12E8B.7CA36570]
PTWA works by basically creating "paint" out of metallic materials. A
wire feedstock is first fed into a highly-charged cathode. This
atomizes the feedstock, which is then sprayed onto a surface with
forced gas. The high kinetic energy of the particles means that they
flatten on impact with the surface of the target. They then quickly
harden. This has the effect of both depositing even amounts of material
onto a surface and of "leveling" the surface by naturally filling in
pits and gouges.
In most PTWA processes, varied materials will be used to build
multi-layer coatings. When witnessed first hand, the plasma coating
process looks similar to spray painting, but with a bright light where
the paint emerges.
The plasma coating process itself is not new. It's been a key
ingredient for making aluminum engine blocks that can withstand
repeated pressure without a cast iron sleeve in the cylinder bores. In
the automotive manufacturing process, PTWA has become a common element.
High-end vehicles such as the Nissan GT-R and Ford Mustang GT500 Shelby
utilize plasma coating to improve friction surfaces and reduce weights
by adding strength to parts made of lighter-weight materials.
[7][cid:image006.jpg at 01D12E8B.7CA36570]
For remanufacturing, pioneering use of plasma coating began with
Caterpillar and others in the diesel engine realm, using it to
refurbish high-mileage or high-use engine blocks that would otherwise
be very expensive to replace. PTWA can be used on cast iron, aluminum,
or nearly any other metal or alloy.
The process for Ford is to take worn, high-mileage engines and use
plasma coatings to refurbish and repair the engine block, especially
the cylinders, as the first step towards creating a like-new engine
that can be used again.
Larry - Cleveland
References
1. http://www.gizmag.com/ford-plasma-engine/40728/pictures#1
2. http://www.gizmag.com/ford-plasma-engine/40728/pictures#2
3. http://www.gizmag.com/ford-plasma-engine/40728/pictures#3
4. http://www.gizmag.com/ford-plasma-engine/40728/pictures#4
5. http://www.gizmag.com/ford-flex-2010-wheat-straw-reinforced-plastic/13419/
6. http://www.gizmag.com/ford-plasma-engine/40728/pictures#3
7. http://www.gizmag.com/ford-plasma-engine/40728/pictures#5
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-------------- next part --------------
Unsleeved aluminum motorcycle cylinders can be re-plated by third party
vendors, though I have no direct experience with that.
Be interesting to see if the process described below will eventually
compete with ordinary sleeving of an iron block.
GD
__________________________________________________________________
From: Larry - Ohio Time <Larry at ohiotimecorp.com>
To: detomaso at poca.com
Sent: Friday, December 4, 2015 9:01 AM
Subject: [DeTomaso] whats old is new again
When an engine fails or becomes very worn, it is usually pulled from
the vehicle and scrapped. Ford wants to change that by utilizing a
high-tech plasma process to remanufacture broken engines. The process
reduces carbon emissions by about half when compared to making a new
engine to replace the old one, and results in a like-new engine
block.
. [1]When an engine fails or becomes very
worn, it is usually pulled from the vehicle and ...
. [2]When witnessed first-hand, the plasma
coating process looks similar to spray painting, but with a bright
...
. [3]The process for Ford involves taking
worn, high-mileage engines and using plasma coatings to refurbish and
...
. [4]The process being used was originally
developed for engine performance enhancement
The goal is to extend the performance of a vehicle by lengthening its
lifespan, thus reducing its overall environmental footprint. It ties
in
with other research being done by Ford to include [5]vegetable fibers
in plastics and soy fibers in foam and cloth.
The process was originally developed for engine performance
enhancement, says Juergen Wesemann, manager of Vehicle Technologies
and
Materials, Ford Research and Advanced Engineering. The Plasma
Transferred Wired Arc (PTWA) thermal spray process applies a coat to
an
engine block which helps bring it back to original condition. This
removes the need for additional heavy parts.
[6][cid:[1]image005.jpg at 01D12E8B.7CA36570]
PTWA works by basically creating "paint" out of metallic materials. A
wire feedstock is first fed into a highly-charged cathode. This
atomizes the feedstock, which is then sprayed onto a surface with
forced gas. The high kinetic energy of the particles means that they
flatten on impact with the surface of the target. They then quickly
harden. This has the effect of both depositing even amounts of
material
onto a surface and of "leveling" the surface by naturally filling in
pits and gouges.
In most PTWA processes, varied materials will be used to build
multi-layer coatings. When witnessed first hand, the plasma coating
process looks similar to spray painting, but with a bright light
where
the paint emerges.
The plasma coating process itself is not new. It's been a key
ingredient for making aluminum engine blocks that can withstand
repeated pressure without a cast iron sleeve in the cylinder bores.
In
the automotive manufacturing process, PTWA has become a common
element.
High-end vehicles such as the Nissan GT-R and Ford Mustang GT500
Shelby
utilize plasma coating to improve friction surfaces and reduce
weights
by adding strength to parts made of lighter-weight materials.
[7][cid:[2]image006.jpg at 01D12E8B.7CA36570]
For remanufacturing, pioneering use of plasma coating began with
Caterpillar and others in the diesel engine realm, using it to
refurbish high-mileage or high-use engine blocks that would otherwise
be very expensive to replace. PTWA can be used on cast iron,
aluminum,
or nearly any other metal or alloy.
The process for Ford is to take worn, high-mileage engines and use
plasma coatings to refurbish and repair the engine block, especially
the cylinders, as the first step towards creating a like-new engine
that can be used again.
Larry - Cleveland
References
1. [3]http://www.gizmag.com/ford-plasma-engine/40728/pictures#1
2. [4]http://www.gizmag.com/ford-plasma-engine/40728/pictures#2
3. [5]http://www.gizmag.com/ford-plasma-engine/40728/pictures#3
4. [6]http://www.gizmag.com/ford-plasma-engine/40728/pictures#4
5.
[7]http://www.gizmag.com/ford-flex-2010-wheat-straw-reinforced-plastic/
13419/
6. [8]http://www.gizmag.com/ford-plasma-engine/40728/pictures#3
7. [9]http://www.gizmag.com/ford-plasma-engine/40728/pictures#5
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References
1. mailto:image005.jpg at 01D12E8B.7CA36570
2. mailto:image006.jpg at 01D12E8B.7CA36570
3. http://www.gizmag.com/ford-plasma-engine/40728/pictures#1
4. http://www.gizmag.com/ford-plasma-engine/40728/pictures#2
5. http://www.gizmag.com/ford-plasma-engine/40728/pictures#3
6. http://www.gizmag.com/ford-plasma-engine/40728/pictures#4
7. http://www.gizmag.com/ford-flex-2010-wheat-straw-reinforced-plastic/13419/
8. http://www.gizmag.com/ford-plasma-engine/40728/pictures#3
9. http://www.gizmag.com/ford-plasma-engine/40728/pictures#5
10. mailto:DeTomaso at poca.com
11. http://poca.com/mailman/listinfo/detomaso_poca.com
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