EFFICIENCY AND EMISSIONS OPTIMISATIONOF GEARS AND …€¦ · rewitec gmbh target markets 20.11.19...

REWITEC GmbH20.11.19

EFFICIENCY AND EMISSIONS OPTIMISATION OF GEARS AND ENGINES BY SILICON COATING

ENGINE EXPO 2018, REWITEC GMBH, STEFAN BILL, CEO

Efficiency and Emissions Optimization of Combustion Engines by Silicon Coating

Dipl.-Ing. Stefan Bill, Managing Director

REWITEC GmbHREWITEC GmbH

COMPANY AND PRODUCTSREWITEC®

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• Establishment in 2003

• Developer, manufacturer and distributor of nano and micro particle based surfacerefinement products for the protection and the repair of tribological systems

• Patents Europe, China, USA

• World wide sales network

• Co-Founder and Managing Partner: Stefan Bill

• Acquisition by CRODA in 2019

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Products

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Target Markets

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WIND ENERGY- ONSHORE- OFFSHORE

INDUSTRY- STEEL- CEMENT- MINING- OIL, GAS

SHIPPING- MARINE- INLAND- YACHTS- SUBMARINE

AUTOMOTIVE- CONSUMER- OEM- MOTORCYCLES- RACING- OLDTIMER

REWITEC GmbH

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Higher Efficiency and longer Lifetime for engines withPowerShot®

Products W100

REWITEC GmbH

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Higher Efficiency and longer Lifetime for gearboxes withDuraGear®

Products W100

REWITEC GmbH

Products ChainSpray

Longer chain lifewith REWITEC®

ChainSprays

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TECHNOLOGYREWITEC®

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REWITEC GmbH

Step 3New metal-ceramic surface

Original material properties will beimproved in terms of friction, temperature and wear significantly

Step 2Chemical reaction

The coating particles ceramize themetal surfaces in mixed friction zones

Step 1Chemical-physical process

The product uses the lubricant ascarrier to the mixed friction zones

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The coating process


SCIENTIFIC TESTSREWITEC® IN ACTION

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REWITEC GmbH

2-Disc Assembly Rolling Wear Tests

Competence Center ofTribologyMannheim-Germany

Scientific tests

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Stress value: 1 GPa (normal force 2150 N)Rotating speed: 424 rpm / 339 rpm, slip 20 %Test-duration: 39,3 hTemperature: oil inlet temperature 60 °CFriction coefficient: µ=normal force/friction force


Scientific tests2-Disc assembly rolling wear test

REWITEC GmbH

Scientific tests2-Disc assembly rolling wear test

VW first fill manual gearbox oil

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Steel disc treated without REWITEC® Steel disc treated with REWITEC®

(1 GPa; 424 rpm / 339 rpm, slip 20 %; 40 h; 60 °C)

REWITEC GmbH

• Red graph without REWITEC®

• Blue graph with REWITEC® added after 20 hours• Green graph with REWITEC® added at the beginning• Reduction of the surface roughness (Ra) due to wear up to 58 % • Reduction of the friction force up to 22 %

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Scientific tests2-Disc assembly rolling wear test –wind turbine oils

REWITEC GmbH

Rz, before = 2.97 µm Rz, after = 1.50 µm (- 49 %)Ra, before = 0.287 µm Ra, after = 0.186 µm (- 35 %)

Fuchs Pentosin EG FFL-7A with REWITEC® added after 20 h. (Friction reduction – 41 %)

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Scientific tests2-Disc assembly rolling wear test –Automotive gear oils

Rewitec® application

REWITEC GmbH

Rz, before = 2.57 µm Rz, after = 1.35 µm (- 47 %)Ra, before = 0.264 µm Ra, after = 0.158 µm (- 40 %)

DTM automotive gear oil with REWITEC® added after 20 h. (Friction reduction – 55 %)

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Scientific tests2-Disc assembly rolling wear test –Automotive gear oils


REWITEC GmbH

Oil analyses of the CASTROL X320

Freshoil sample CASTROL X320 Freshoil sample CASTROL X320 after REWITEC DuraGear W 100The following elements were foundadditionally in the tested oil after theapplication of the REWITEC DuraGear product:

- Si (Silicon up to 175ppm)- Al (Aluminium up to 138ppm)- Fe (Ferrum up to 6ppm)- K (Potassium up to 9 ppm)

These elements are a part of theREWITEC formulation. All the otherelements and additives in theoil are same concentration before and after the REWITEC DuraGear application.


Scientific tests2-Disc assembly rolling wear test –steel vs. phosphated discs

2-Disc Assembly Rolling Wear Tests with VW first fill manual gearbox oils

Stress value: 1 GPa (normal force 2150 N)Rotating speed: 424 rpm / 339 rpm, slip 20 %Test-duration: 39,3 hTemperature: oil inlet temperature 60 °C

REWITEC GmbH


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• Left: Standard steel disc• Right: Phosphated disc

StandardPhosphated

REWITEC GmbH


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Standard steel disc without REWITEC® Phosphate disc withoutREWITEC®

REWITEC GmbH


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Standard steel disc with REWITEC® Phosphated disc with REWITEC®

• Difference of the surface roughness up to 77 %


• Reduction of the wear up to 9 %• Reduction of the friction force up to 28 %

Phosphated discwithout REWITEC®

Phosphated discwith REWITEC®



• Graph with REWITEC® steel-steel discs• Reduction of the friction force compared to phosphated discs:

51 % without REWITEC®

33 % with REWITEC®

VW G 052 527 A2 with REWITEC® added after 19 hours 39 minutes



Standard steel discs

REWITEC GmbH

Test parameters:

Test specimens Test discs from previouslydamaged camshaft

Camshaft manufacturer German engine manufacturer

Test period 40 h

Lubricant Engine Oil SAE 10W-40 of the engine manufacturer

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Scientific tests2-Disc assembly rolling wear test –Engine oil


Camshaft disc before testing withoutREWITEC® :• Large grooves

Camshaft disc after testing withoutREWITEC® :• Clearly visible grooves and micrograph• Light reduction of friction

after

before


REWITEC GmbH

Camshaft disc before testingwith REWITEC® :• Heavy grooves in the right

section before the test-run

Camshaft disc after testing withREWITEC® :• Grinding pattern completely

disappeared• Grooves significantly reduced• Significant reduction of frictionafter

before

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REWITEC GmbH

With REWITEC®

Without REWITEC®

• Upper graph without REWITEC®

• Lower graph with REWITEC®

• Reduction of the friction force up to 45 %• Reduction of the surface roughness up to 73 %*)*) 50% less surface roughness can lead to a 20-fold life expectancy– thesis of Dr.-Ing. Michael Gleß.

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Scientific testsPin-on-disk Tribometer

spring system

heater

ball attachment

sample

oil

electricmotor

thermal insulation

axial cylindrical roller bearings

Sliding

Rolling

disk ball

REWITEC GmbH

Measurement procedure:

I. Run-in of the contact until stableinterface conditions are established

II. Additive is added

III. “2nd Run-in”: improved tribo-contactis developed due to additive effects

IV. New stable interface conditions areestablished

V. Difference of friction levels beforeand after additiv addition:Reduction of friction due to additive

Additive is added

(schematic representation of typical measurement)

Decrease of friction due to additive

Initial run-in of contact

Stable interfaceconditions after

run-in

2nd run-inprocess

Figures shown laterfocus on this region

rela

tive

fric

tion

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Scientific testsPin-on-disc test


Scientific testsPin-on-disc test – Honda Engine Oils

Following very low viscosity oils were tested with REWITEC®:

• Motor oil Honda Ultra Next:• 0W-8

• Motor oil Honda Ultra Green:• 0W-25



Honda Ultra Next motor oilRoom temperature; load 5 N; 4000 min-1

Friction reduction 30 % after 1 hour



Honda Ultra Green engineoilRoom temperature; load 5 N; 4000 min-1

friction reduction 35 % after 1 hour friction reduction 27 % after 1 hour

Honda Ultra Green engine oil70°C; load 5 N; 4000 min-1


Scientific testsSealing Durability of Radial Shaft Seals


Scientific testsSealing Durability of Radial Shaft Seals

Test 1: Engine oil (10W-40) without REWITEC® Test 2: Engine oil (10W-40) with REWITEC®

None of the test pairings showed significant signs of abrasion


Scientific testsSealind Durability of Radial Shaft Seals

Test 1: Engine oil (10W-40) without REWITEC® Test 2: Engine oil (10W-40) with REWITEC®

None of the test pairings showed significant signs of abrasion


EXAMPLES OF APPLICATIONWIND ENERGY | AUTOMOTIVE | MARINE | INDUSTRY

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REWITEC GmbH

• Gasoline and diesel engines• Gearboxes• Rear axles, differentials• Joints and shafts• Bearings of all kind• Drive chains

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Examples of application:Passenger cars, sports cars, bikes, oldtimers…


Michael Krumm:

• German professional racing driver• Winner of the 2011 FIA GT1 World Championship• Mulitple participants of the 24 h of Le Mans, best finish 3rd• Brand ambassador for

Nissan-NISMO


Examples of application:Nissan GT-R R32 engine treatment by M. Krumm

Test dynamometer:Dynapack Chassis Dynamometers Evolution 3000

Baseline: 281 BHP / 348 Nm

Treatment with REWITEC® PowerShot® L (29.01.2016)Improvement after 2 h: +16 BHP / 15 Nm

Additional transmission treatment with REWITEC® G5 (30.01.2016)

Complete end-result-improvement after 6 weeks: +28 BHP


Examples of application:Nissan GT-R R32 engine treatment by M. Krumm

29.01.2016 17.03.201629.01.2016

REWITEC GmbH

Examples of application

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Application in Porsche Cayenne GTS:

All measurements performed in 4th gear, ratio 1.16 : 1

REWITEC GmbH

Measurement Date NEDC 90 km/h 110 km/h Particles Mileage

Consumption l/100 km l/100 km l/100 km g/km

First 30.05.2007 6,59 5,59 7,13 0,077 160,218

Second 13.06.2007 6,31 5,47 6,95 0,028 164,450

Reduction -4,2 % -2,2 % -2,5 % -63,6 %

Fachhochschule Frankfurt am Main, 15.06.2007


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Coating and analysis of a VW Touran :

REWITEC GmbH


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Toyota LandCruiser 1996 Diesel 4.2 L 24 valve 4 WD. From Vladivostok (Russia) to London & BackRewitec in engine, gearbox and differantials

REWITEC GmbH


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Application in a new truck Peterbilt 579:


SENTIENT SCIENCEREWITEC® LIFETIME CALCULATIONS

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REWITEC GmbH

DigitalCloneMaterials-Based Computional Testing

Sentient Science

LIFETIME CALCULATIONS

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Analysis of REWITEC® DuraGear®

W100 Lifetime Effecton GE 1.5 MW Winergy 4410.2 Gearbox


Mixed-EHL

Right: Surface pressureof two smooth surfacesinteracting withREWITEC®

Mixed-EHL Solution for Life Prediction

Left: Surface pressure of two rough surfacesinteracting withoutREWITEC®


Sentient Science

LIFETIME CALCULATIONS


CONCLUSIONAT A GLANCE

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REWITEC GmbH

Conclusion

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• Friction reduction• Wear reduction• Roughness reduction• Temperature reduction

Ø Higher efficiencyØ Longer lifetimeØ Higher reliability


FOR YOUR ATTENTION

Many thanks

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REWITEC GmbH

REWITEC GmbH

Dr.-Hans-Wilhelmi-Weg 1

35633 Lahnau, Deutschland

Telefon: +49 (0) 6441 / 445 99-0E-Mail: [email protected]

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EFFICIENCY AND EMISSIONS OPTIMISATIONOF GEARS AND …€¦ · rewitec gmbh target markets 20.11.19...

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