Gehring Optimizes Coated Cylinder Bores with Laser Roughening

Technology capable of thermally coating cylinder bores is a highly sought-after solution. High performance roughening is required to produce a reliable bond between the layer and substrate, ensuring all aspects of functionality. A positive interlocking connection is achieved by undercutting and the complete filling of the profile’s roughness; microscopically and evenly sprayed materials are crucial requirements for layer adhesion.

The purpose of laser roughening is a micro-positive interlocking connection across the entire surface, enabling a high level of adhesive strength, resulting in an appropriate and robust layer in all directions.

Blast parameters and process kinematics allow roughening topographies for both spiral profiled grooves or enclosed cavities. When energy enriched beams of light identify the material, the energy is absorbed locally and converted into heat. When the appropriate parameters are selected, formation of the profile roughness is ideally matched to the function, for both aluminum and cast-iron materials.

Operating costs are relatively low, due to the lack of mechanical machining typically associated with high tooling costs. Additionally, laser roughening delivers substantial material cost savings, due to the high levels of adhesive strength achieved with low roughness.

The compact design of laser spindles allows for two identical cylinder bores to be machined simultaneously. The hollow-shaft motor and stationary submersed optical system enables operation, virtually without vibration.

An industrial based sensor is used to monitor the process, particularly during the set-up stage. The optical equipment for the fully automated roughening module, with an optimized footprint, includes an extraction system and coolant device for the laser beam and spindle sources.

Our years of expertise in engine-based technologies, including a wide variety of performance categories, demonstrates laser roughening’s innovative and cost-effectiveness for today’s manufacturing processes. Laser roughening is applicable for pre-treating all conventional thermal coating processes.

Gehring has extensive expertise across all areas of the “Laser roughening, coating and honing” process chains. Our synchronized process steps result in reduced friction and wear-resistant cylinder surfaces. 

About Gehring:

For more than 90 years, Gehring has been the leader in the domain of honing technology, supplying cutting-edge surface finish technology solutions for internal combustion engines, gears and numerous other industrial applications. As a global technology leader, the company is represented internationally in key markets in the automotive and supplier industries, hydraulics and pneumatics, as well as aerospace sector.

Gehring’s product portfolio ranges from individual honing stones to honing tools, including gauging and automation solutions; up to integrated honing systems. Digital applications, services and innovative technologies for honing, laser structuring, roughening and coating complete the product portfolio.

With standalone made-to-measure solutions for stator prototype development and small-scale series production, as well as fully automated new system solutions for electric motor production lines, copperING‘s product portfolio compliments that of its new partner Gehring. The Gehring group therefore offers the full gamut of technologies for vehicle drives – from conventional solutions to hybrid technologies and even integral electrification.

The Gehring Group has approximately 800 employees, headquartered in Ostfildern, Germany, and additional locations in Naumburg and Wernigerode, Germany, as well as in the USA, China, India, Italy, UK, France, Brazil and Mexico.