Abradable powder coatings

Abradable Powder Coatings (APC), also known as Additive/Abradable Powder Coatings (AAPCs), are a class of abradable materials that are applied using standard powder coating technology. They are used for clearance control, sealing and lubrication over a wide range of temperatures in oiled and dry devices. Application of the coatings is inexpensive and environmentally friendly.[1]

Abradable coatings are made up of materials that will abrade, or wear off, when they rub against a mating surface. The coating acts as a sacrificial layer when it comes in contact with another surface so that the base material underneath is protected and remains unharmed.[2][3]

Abradable Powder Coatings safely reduce operating clearances and friction to improve the efficiency of compressors, pumps, engines, blowers, etc. A Tier 1 automotive supplier reports increased volumetric efficiencies and enhanced sealing on supercharger rotor sets through the use of a patented abradable powder coating.[4] [5] [6] [7]

Abradable Powder Coating provides engine benefits such as higher efficiency, reduced noise and greater durability when applied on pistons. The coating can be applied thick so that during the initial operation the coated component wears in until its ideal geometry is reached under temperature and load. Normally there is no change to the base metal component dimensions and the parts require no post-machining before assembly.[8]

Abradable Powder Coatings (APC's) on piston skirts and lands are advancing performance and life of cylinder kits in three principal ways:

  1. APC coatings lap in to permanently improve piston-to-bore fit, reducing unwanted motion and creating a thin, resilient oil film for lower friction with less wear.
  2. Better piston fit in each bore keeps rings square to the cylinder and settled for improved sealing, heat transfer and oil management.
  3. All across the skirts (not just at the gage point) APC safely removes Integrated Skirt Clearance (ISC) volume between piston skirt and bore surface to limit destructive motion and accelerations between cylinder kit components.[9]

These coatings can dramatically improve efficiency in oil pumps if, for example, less expensive components such as cast pump housings are used with reasonably loose tolerances. An abradable coating can be a highly cost-effective method of improving the tolerances and efficiency of the impeller-housing combination without resorting to much more costly machining of the original components. As an incidental benefit, if an abradable coating has allowed an efficiency increase in a pump, it may be possible to downsize the pump to be used while still delivering the necessary flow/pressure and so save weight or packaging space.[10]

References
  1. "Introduction to abradable powder coatings" Archived 2015-09-24 at the Wayback Machine, engine technology international, Retrieved on 7 October 2015.
  2. "Abradable Coating", Corrosionpedia, Retrieved on 7 October 2015.
  3. "Powder Coating Plus". Sunday, 7 February 2021
  4. Parks, Jim "Building on A Tradition of Excellence, Eaton Superchargers Surge Ahead In Power And Performance", 13 February 2007. Retrieved on 7 October 2015.
  5. Morey, Bruce "Improving The Atmosphere", Manufacturing Engineering, 13 November 2013. Retrieved on 7 October 2015.
  6. Sawyer, Christopher A. "GM'S LS9 V8: Life Under Pressure ", Automotive Design and Production, 1 October 2008. Retrieved on 7 October 2015.
  7. "One Blown Bat Outa Hell" Archived 2016-03-06 at the Wayback Machine, Tom Henry Racing, Retrieved on 7 October 2015.
  8. Suman, A.; Shamis, D. "Clearance Control Coatings - Low Cost, Abradable, Lubricious", SAE International, 28 September 2010. Retrieved on 7 October 2015.
  9. Suman, Andy " Abradable Piston Coatings – Better fit for more power and durability ", engine professional, AERA International, April – June 2020. Retrieved on 11 August 2020.
  10. Cooper, Dr. Dave "Focus: COATINGS – Film Stars" Archived 2016-11-07 at the Wayback Machine, race engine TECHNOLOGY, September/October 2016. Retrieved on 17 October 2016.
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