Fraunhofer Institute for Mechanics of Materials IWMThe overall objective of the project was to increase the resilience, reliability, and service life of components in gas engines that are subject to extreme tribological stress. Concepts were particularly developed for more efficient engines with increased mechanical efficiency that are low in emissions. This was achieved through the use of improved materials and lubricants for engine components in areas subject to the highest thermal and tribological stresses, especially in the area of valve guidance and valve seats.
Gas engine development: Energy-efficient system technologies with integral robustness – GESIR. Subproject: Development of test concepts and evaluation of the tribological behavior of valve components and lubricants
Completed research project
Project description
Achieving climate neutrality in the economy is a major challenge. By 2030, CO2 emissions are to be reduced by 55% compared to 1990 levels. To achieve this goal, storage technologies are needed to store electricity generated from renewable sources. Power-to-X offers interesting solutions for storing the electricity generated and converting it back into electricity when needed. Gas engines that can flexibly use different renewable fuels are used for reconversion. In the joint project GESIR (Gas Engines with Energy-Efficient System Technologies and Integral Robustness), the MikroTribologie Centrum µTC worked together with industry partners on solutions to increase the load capacity, reliability, and service life of tribologically highly stressed components in gas engines. The aim was to enable further improvements in efficiency and reduce emissions.
Fraunhofer IWM subproject:
Development of test concepts and evaluation of the tribological behavior of valve components and lubricants
One of the greatest challenges for gas engines is the lubrication conditions in valve seats and guides. High temperatures and low lubricant supply can cause adhesive wear on the components. High-speed oscillation tests (HOGO) were carried out to investigate the friction behavior and wear of valve guides in application-oriented conditions. The test setup is an in-house development that has been specially adapted to the tribological challenges in valve trains. This allows engine-like conditions to be set in terms of lubrication, temperature, and transverse forces on the valves. Components from the engine are used for the tests. This enables a direct comparison of lubricants, valve stems, and guide sleeves at an application-oriented test level. Expensive engine test runs can thus be avoided.
Transfer of project results to the following Fraunhofer IWM R&D services for companies:
- Tribological evaluation of valve components and lubricants in gas engines
- Application-oriented comparison of lubricants, valve stems, and guide sleeves
