New EcoTough®-coated pistons reduce friction losses, improve wear resistance and can be introduced in volume production as a running change
SOUTHFIELD, Mich. -- Federal-Mogul Corporation (NASDAQ:FDML), a leading global supplier of technologies that improve powertrain efficiency and enhance vehicle safety, 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 percent, as well as reduced CO2 emissions, 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 EcoTough-coated piston also fulfills the most stringent environmental standards and contains no toxic solvents.
"Federal-Mogul's global strategy is to develop leading-edge technologies and innovative solutions that improve fuel economy, reduce emissions and enhance vehicle performance," said Rainer Jueckstock, Federal-Mogul senior vice president of Powertrain Energy. "EcoTough is a proven solution that will help OEMs meet the stringent regulatory requirements for their vehicles."
Customer and governmental mandates to reduce CO2 emissions and fuel consumption makes the reduction of parasitic friction losses between the piston and the cylinder bore a priority for vehicle manufacturers. At the same time, the power output-per-liter of engine displacement is increasing as engines are downsized and boosted by turbo- or super-charging, subjecting pistons to higher mechanical and thermal loads.
In laboratory testing, EcoTough-coated pistons show an 18-percent piston friction loss reduction and an improvement of up to 3 percent in entire engine parasitic loss. Engine bench tests confirm a fuel economy benefit of 0.4 to 0.8 percent 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 offers vehicle manufacturers an attractive combination of benefits -- a reduction in fuel consumption and CO2 emissions, coupled with improved wear resistance and straightforward implementation," said Dr. Frank T.H. Doernenburg, Federal-Mogul's director of technology, pistons and pins. EcoTough-coated pistons are currently in production, having recently been introduced on a high volume vehicle from a major European manufacturer.
Federal-Mogul Corporation is a leading global supplier of powertrain and safety technologies, serving the world's foremost original equipment manufacturers of automotive, light commercial, heavy-duty, industrial, agricultural, marine, rail, off-road and industrial vehicles, as well as the worldwide aftermarket. The company's leading technology and innovation, lean manufacturing expertise, as well as marketing and distribution deliver world-class products, brands and services with quality excellence at a competitive cost. Federal-Mogul is focused on its sustainable global profitable growth strategy, creating value and satisfaction for its customers, shareholders and employees. Federal-Mogul was founded in Detroit in 1899. The company is headquartered in Southfield, Michigan, and employs 43,000 people in 34 countries. Visit the company's Web site at www.federalmogul.com