Project description
New nanocoatings reduce friction and increase engine performance
Friction and wear between moving mechanical components of an engine affect its fuel economy, emission characteristics and lifetime. In particular, bearings and pistons account for more than 30 % and 60 % of the total friction lost, respectively. The EU-funded TVARC project is developing nanocoatings that improve resistance to friction between components. At the core of TVARC’s concept is a thermionic vacuum arc system, a unique machine that can apply a nano thin film to improve the frictional properties between moving parts. It can reduce friction in bearings and pistons by 30 %. In terms of value, this translates to EUR 45 million cost savings and over 450 million tonnes of CO2 emission reductions.
Objective
Friction, the resistance to motion that occurs when two surfaces are in contact, is close to one quarter of all energy consumed worldwide. Whether it is transportation, industrial, manufacturing, power generation or in the residential sector (housing equipment), friction is everywhere and represent 20% of the world’s total energy consumption. Within the transportation sectors, the automotive and bearing industries are facing the major difficulties with friction. Car consumes about 169 liters of fuel only to overcome mechanical friction in the powertrain, bearings contribute to 32.5% of the total friction lost, pistons 59.5%. In Europe, cars are responsible for around 12% of total EU CO2 emissions and recent EU regulations have introduced stringent limitations for the average car CO2 emission. To provide enhanced productivity with cars that have less environmental impact, low fuel consumption and improved operating efficiency, the automotive and bearing industries are today facing a major challenge in reducing frictions which consumes a great deal of energy and causes wear one of the main reasons for failure of a material.
To address the frictional and wear challenge, TVARC has developed a new concept of nano-material coating which provide improved frictional behaviors between components. TVARC innovation is a Thermionic Vacuum Arc (TVA) system, a unique machine able to apply a nano-dimensional thin film of material (i.e. Boron, Graphite, Diamond like carbon, hexagonal Boronnitride, Molybdenum disulfide, Titanium Nitride, Silicon Carbide, Zirconium dioxide or Aluminum oxide) to improve frictional properties between moving parts. Thanks to TVARC, 30% friction reduction (3x higher than current competing solution) can be provided to bearings and pistons which, in term of value, could translate in €145 million economic savings and 453 MtCO2 emission reductions. Targeting engine, motor and car manufacturers,TVARC has an important potential market of over 1000 customers
Fields of science
- engineering and technologymechanical engineeringtribologylubrication
- natural scienceschemical sciencesinorganic chemistrytransition metals
- engineering and technologynanotechnology
- engineering and technologymaterials engineeringcoating and films
- engineering and technologyenvironmental engineeringenergy and fuels
Programme(s)
Funding Scheme
SME-1 - SME instrument phase 1Coordinator
26040 ESKISEHIR
Türkiye
The organization defined itself as SME (small and medium-sized enterprise) at the time the Grant Agreement was signed.