Federal-Mogul Corporation has developed a new coated piston for gasoline engines that combines the properties of low wear and low friction in a single application. The new EcoTough-coated piston offers superior wear resistance and reduces fuel consumption up to 0.8% compared to conventional piston coatings.
The EcoTough-coated piston is compatible with existing and advanced cylinder bore finishes and can be introduced seamlessly in volume engine production as a running change.
The key behind the EcoTough-coated piston technology is the composition of the coating, which is comprised of solid lubricants, including graphite, molybdenum disulfide (MoS2) and carbon fiber.
In applications requiring additional protection, for example with a rough cylinder honing structure, the EcoTough-coated piston offers a greater coating thickness than pistons with conventional coatings. The technology suits high-volume manufacturing and is less sensitive to pre-treatment process variations, resulting in greater robustness and minimized dispersions in performance, the company says. The EcoTough-coated piston also fulfills the most stringent environmental standards and contains no toxic solvents.
In laboratory testing, EcoTough-coated pistons show an 18% piston friction loss reduction and an improvement of up to 3% in entire engine parasitic loss. Engine bench tests confirm a fuel economy benefit of 0.4 to 0.8% in normal driving conditions. In wear resistance testing at full load and after 50 cold-start cycles, EcoTough-coated pistons demonstrate a major reduction in wear on the piston surfaces in contact with the cylinder.
EcoTough-coated pistons are currently in production, having recently been introduced on a high volume vehicle from a major European manufacturer.