Diamond Like Carbon (DLC) on bucket type cam followers
I am rebuilding a double overhead V-6 engine and have noticed wear on the bucket cam followers and would like to know if anyone has had a good result with DLC coatings applied to the cams and or followers?
This technology is beginning to be used in mass produced engines. Nissan and Caterpillar are both actively working with DLC coatings. There are a number of SAE Technical Papers documenting some of the recent research, implementation, etc. The annual conference of the Society of Vacuum Coaters is another source of information on automotive applications.
If designed, manufactured and maintained properly, a cam and bucket
follower interface would not benefit from an (expensive) DLC surface
treatment. The reason is that when the parts are properly designed and
manufactured, the contact between the bucket and cam lobe should always
be hydrodynamic (ie. the parts separated by a thin dynamic oil film),
except during start-up
and stopping. As long as the cam lobe and bucket surfaces have
adequate compressive fatigue strength for the magnitude and number of
load cycles it must endure, based on the hydrodynamic oil film pressures
in the local contact zone, then the parts should have adequate life.
Adding
a very thin, but very hard, DLC surface won't really help fatigue life
either. The classic failure mode for this type of structure (ie. a thin
hard case over a softer core under high localized contact stresses), is
case spalling due to sub-surface initiated shear fractures. What this
means is that it does no good to have a very hard, high strength case
unless you have a core material with very high shear strength to back it
up.
DlC's are great due to their hardness and low inherent
friction properties. And they have their place when utilized
properly. They are most beneficial for boundary-type contact
conditions, where oils or greases cannot be used, or where a loss of
lube may occur. But an engine valvetrain bucket follower and cam lobe
would not likely have these operating conditions. So save your money.
You mentioned one of the prime reasons to consider DLC(gate valve) - low friction. To increase engine efficiency, low viscosity lubricants are used. This means the metallic surfaces that move will be more likely to wear, so a wear-resistant coating improves part durability. Also, the low friction reduces powertrain losses for reduced fuel consumption.
DLC coatings are applied by vacuum processes (PVD or PACVD) with a
thickness of ~ 2-5 micrometers on surfaces that have already been highly
finished (combinations of grinding, polishing, etc.), usually with a
roughness of Ra ~ 0.1 to 0.2 micrometers. Maximum roughness should be
Rz ~ 0.4 micrometers, otherwise the coating essentially acts as a
microscopic grinding wheel and degrades the mating surface during
operation. Anyway, DLC coatings do not require subsequent finishing
when the substrate surface has been properly finished. "Restoring" a
previously worn surface is not really practical, because the surface is
too rough (> Ra ~ 0.4).
"EP additives like ZDTP work well in gear oils, but they have properties that are detrimental when used in engine oils."
If
this refers to Zinc dialkyldithiophosphates it is not completely
accurate. These compounds are classical antiwear additives, generally
accepted as forming complex phosphate-based glasses on iron or steel
surfaces such as cams and lifters under conditions of moderate
load. Some form of AW is necessary for most engines to protect the valvetrain during start ups, and zinc compounds serve this purpose
in nearly all current engine oils and most hydraulic fluids. They also
function as anti-oxidants, protecting the oil from high temperature
chemical degradation. I don't recall how they interact with DLCs, but
this has been extensively researched so there is literature on the topic
for those interested.
Extreme pressure additives are usually
based on sulfur, forming iron sulfides under conditions of high load
found in the low speed sliding contacts of hypoid and bevel gearsets in
axles. They are different chemicals suited for separate
applications. They are not generally suitable for crankcase oils, part
of the reason why gear oils have different SAE viscosity grades despite
comparable viscosity values (in some cases) to engine oils- to avoid
misapplication.
As I have pointed out elsewhere, AW additives
function at very low levels- consider hydraulic oils can get by for
thousands of hours on ca. 50 ppm- and the majority present in engine
oils is included for oil durability (i.e. long drain). In cases of
premature engine wear one would expect packing the oil full of more ZDDP
to have less real effect than making a parts change or selecting a
different ZDDP chemistry better 'tuned' to activate at a more suitable
temperature/pressure regime.
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