Setembro 2025 vol. 12 num. 1 - XXXII Simpósio Internacional de Engenharia

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Nova geração de anéis com recobrimento PVD para motores flex fuel de alta performance

New generation of PVD coated rings for high performance flex fuel engines

MAZUCO, Felipe ; REZENDE, Luiz Felipe ; BRUNO, Rafael Antonio ; ARAUJO, Juliano Avelar ;

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Um problema já conhecido para revestimentos de anel de pistão em combinação com o uso de etanol são as micro trincas e destacamentos localizados. Melhorias nos revestimentos de CrN foram feitas junto com o desenvolvimento dos motores flex. No entanto, com a introdução de novas legislações no Brasil para aumentar a eficiência dos motores e reduzir as emissões, as montadoras foram levadas a atualizarem seus motores em termos de hardware e calibração levando a maiores cargas termomecânicas. Os revestimentos de CrN otimizados foram impactados diretamente pelo ambiente tribológico severo e retornaram a sofrer ocorrências de micro trincas e de destacamentos localizados. Este trabalho aborda a última geração de revestimentos de PVD, dopando o CrN com Alumínio e adotando uma estrutura em nanocamadas. O Nitreto de Cromo Alumínio (CrAlN) oferece dureza superior, estabilidade térmica e química aumentadas e a coesão melhorada do revestimento. A arquitetura em nanocamadas, conseguida através da modulação do teor de alumínio, atua como uma barreira para a propagação de trincas. Testes de motor confirmaram que o novo revestimento permanece livre de micro trincas e destacamentos, mesmo sob condições motores flex-fuel altamente carregados.

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A well-known issue with piston ring coatings in combination with ethanol use is the occurrence of microcracks and spalling. Specific improvements in the CrN coatings were made along with the flex fuel engines development. However, the introduction of new legislations in Brazil to increase engine efficiency and lower emissions led the automakers to upgrade their engines in terms of hardware and calibration with the consequence of increased thermomechanical loads. The improved CrN coatings were directly impacted by such harsher tribological environment returning to suffer from microcracks and spalling occurrences. The latest generation of PVD coatings addresses these challenges by incorporating aluminum into CrN and adopting a nanolayered structure. Chromium Aluminum Nitride (CrAlN) offers superior hardness, enhanced thermal and chemical stability, and improved coating toughness. The nanolayered architecture, achieved through modulation of the aluminum content, acts as a barrier for crack propagation. Engine tests have confirmed that the new coating remains free from microcracks and spalling, even under high-load conditions in flex-fuel engines.

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DOI: 10.5151/simea2025-PAP43

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Como citar:

MAZUCO, Felipe; REZENDE, Luiz Felipe; BRUNO, Rafael Antonio; ARAUJO, Juliano Avelar; "Nova geração de anéis com recobrimento PVD para motores flex fuel de alta performance", p. 207-215 . In: Anais do XXXII Simpósio Internacional de Engenharia. São Paulo: Blucher, 2025.
ISSN 2357-7592, DOI 10.5151/simea2025-PAP43

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