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Abstract

The potential for surface engineering solutions to increase the corrosion and wear resistance of diesel valves is examined with regard to operation in residual fuel oil combustion products. The environment in which the exhaust valve operates is discussed. The corrosion test is used to sort the 27 coating treatments and 16 hardfacing alloys examined. H ardfacing materials showing the greatest potential are also evaluated in hot wear tests. As reference materials, En 52 steel, Nimonic 80A, and Stellite 6 are included. Corrosion tests over the temperature range 500–700°C have shown that the surface treatments can be ranked in terms of their composition and expected metal surface temperature. Good corrosion resistance to residual fuel oil combustion products reflects primarily the content of the alloy, the base metal (Fe, Ni, or Co) being of secondary importance. Refractory metals (Ti, Nb, Ta, Mo, and W) and other minor alloying additions do not significantly alter the corrosion behaviour, unless they are present in large quantities. Hot wear tests (650°C, 80 MN m⁻² contact pressure) of candidate hardfacing alloys have also demonstrated the importance of the Cr content of the alloy. This probably results from the ease of formation of a protective glaze, lowering the coefficient of friction and therefore the wear rate. Additions of refractory metals were beneficial. Since optimum wear resistant alloys contained high levels of Mo and vv: they were poor in terms of corrosion resistance. It is therefore necessary to balance wear resistance against corrosion resistance in the selection of materials for residual fuel oil service. Two coating systems, vacuum plasma sprayed Ni–50Cr and a chromised diffusion treatment appeared to have potential as valve surface treatments for improved corrosion resistance; and two hardfacing alloys, Tristelle TS2 and Colmonoy 8, offered balanced behaviour as seat materials with acceptable wear resistance and improved corrosion performance. These materials have been evaluated in the engine tests of three different diesel engine manufacturers.

MST/3157

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Coatings and hardfacing alloys for corrosion and wear resistance in diesel engines

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