Monitoring of a single-mode cw laser process for texturing of aluminium cylinder bore surfaces of combustion engines for coating preparation
Conference on Lasers in Manufacturing (LiM)
Aluminium cylinder crankcases are more lightweight and thermally conductive than their conventional predecessors made of cast iron, but the cylinder bore surfaces must be coated with a wear-resistant material to achieve better or similar tribological performance. Thermally sprayed coatings can only achieve required adhesive strength when applying a roughening process. This enhances the mechanical form fit between the coating and the cylinder bore. The described laser systems technology for texturing cylindrical inner surfaces enables helical trench-like structures to be inserted into the cylinder bore surfaces to improve the adhesion mechanism of the coating to the substrate. The laser based process has additional manufacturing benefits compared to conventional roughening regarding tool wear and soiling of the produced parts. The presented work describes the development of the technology from fundamental process development via application in serial production to inline process monitoring.