New EcoTough Diesel coated pistons reduce friction losses, improve wear resistance and can be introduced in volume production as a running change
Hanover, Germany, September 19, 2012 . Federal-Mogul Corporation (NASDAQ: FDML) has developed a new coated diesel piston that reduces frictional losses in both light and heavy-duty engine applications. This innovation improves fuel economy, CO2 emissions, noise and refinement; all factors that are especially important to commercial vehicle engine designers and fleet operators.
Tests using a single cylinder engine have demonstrated that EcoTough® Coated Diesel pistons reduced friction by up to 13 percent, compared with conventional graphite coatings. The EcoTough coating also has a high wear resistance that can be used in the design process to increase piston skirt clearance, further reducing friction and fuel consumption without compromising NVH and engine durability.
"EcoTough Diesel Coating is part of Federal-Mogul's strategy to develop optimized piston coatings to meet the specific requirements of diesel engines," said Dr. Frank T.H. Doernenburg, Federal-Mogul's director of technology, pistons and pins. "Reducing frictional losses by applying our materials expertise is a critical element in our work with engine manufacturers".
Building on its work with leading vehicle makers who are currently using EcoTough for gasoline applications, Federal-Mogul has optimized the coating's components to meet the requirements of highly loaded diesel engines. EcoTough Diesel uses solid lubricants, including graphite, and a carbon fibre reinforced polymer base to provide lower friction, higher scuff resistance and improved wear resistance.
"A very effective way of reducing friction in an engine is to reduce contact between the piston skirt and cylinder wall," said Doernenburg. "Federal-Mogul has a robust coating application process for series production that delivers the specified thickness necessary to ensure that increased skirt clearance allows no lateral movement of the piston, which would otherwise compromise NVH."
The pistons are compatible with existing and advanced cylinder bore finishes and can be introduced in volume engine production as a running change. The EcoTough material formulation also meets the most stringent environmental standards and contains no toxic solvents.
"Our technology is a proven solution that will help OEMs achieve greater fuel economy and durability for their vehicles," explained Doernenburg. "The reduction of parasitic friction losses between the piston and the cylinder bore is a priority for all vehicle manufacturers. EcoTough provides a simple, cost-effective way of achieving this."
The EcoTough Diesel coating was developed at Federal-Mogul's Piston Production and Development Centre in Nuremberg, Germany. Customer development projects are already underway with major manufacturers in Europe, North America and Asia.
Federal-Mogul Corporation designs, engineers, manufactures and distributes technologies to improve fuel economy, reduce emissions and enhance vehicle safety. The company serves the world's foremost original equipment manufacturers of automotive, commercial, aerospace, marine, rail and off-road vehicles; and industrial, agricultural and power-generation equipment. The company also develops and distributes to the aftermarket an extensive product portfolio with more than 20 of the world's most recognized brands, including ANCO® wiper blades; Champion® spark plugs, wipers and filters; AE®, Fel-Pro®, Goetze®, Glyco®, Nüral® and Payen® engine products; MOOG® chassis parts; and Ferodo® and Wagner® brake products. Federal-Mogul was founded in Detroit in 1899. The company employs 45,000 people in 34 countries, and its worldwide headquarters is in Southfield, Michigan, United States. For more information, please visit www.federalmogul.com.
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