After intensive cooperation in process and technology development, Gehring Technologies GmbH will equip the Volkswagen Group (VW) with the latest laser and honing technology for the production of coated EA211 evo engines. This will not only be in North America, but also on VW’s first plants in China.
The VW engine named EA211 evo has been equipped with the latest technologies to increase efficiency and is also available for natural gas models and plug-in hybrids—playing a strategically important role worldwide in the further development of conventional drives and is one of the most efficient engines on the market. The coating of the cylinder liner is one of the important levers. VW will now install the corresponding production lines in China. For these lines, Gehring received the order to supply the laser roughening and honing machines.
The thermal coating of cylinder bores is a highly sought-after technology for increasing the efficiency of internal combustion engines. Gehring is focusing on optimizing the process chain laser roughening–coating–honing, which is required to produce a strong bond between the coating and the engine block. Gehring’s laser roughening technology brings operative advantages. Apart from cost savings and an improved working environment, there is also a positive effect on the overall engine design. In addition to high adhesive tensile strengths with low roughness, economic advantages take effect in mass production, since no wearing tools are needed and coating material is saved. Both aluminium and cast iron can be pre-machined with the laser refining process.
The Gehring laser roughening machines have two spindles with innovative rotation optics for the simultaneous machining of two-cylinder liners. The coordinated process steps roughening–coating–honing lead to low-friction and wear-resistant cylinder liners, which contribute to more compact and more efficient internal combustion engines.
The process for pre-machining cylinder liners by means of laser, industrialized by Gehring, before coating and honing brings decisive advantages in terms of operating costs, working environment and, above all, friction and heat dissipation—resulting to the optimization of engine efficiency.
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