ARCI Develops Cost-Effective Nanosecond Laser Surface Texturing to Boost Engine Efficiency and Reduce Friction

IC engines lose around 50% of their energy due to friction, with 70%-80% of these losses occurring in the piston-cylinder system, particularly in the piston rings.

Researchers at the International Advanced Research Centre for Powder Metallurgy & New Materials (ARCI), an autonomous R&D centre under India's Department of Science and Technology, have introduced a promising and cost-effective solution to improve engine performance through nanosecond laser surface texturing. This technique aims to enhance tribological performance, which involves reducing friction and wear between moving engine parts like piston rings and cylinder liners. This is a critical factor in improving the efficiency of internal combustion (IC) engines, where frictional losses account for a significant reduction in fuel economy.

IC engines lose around 50% of their energy due to friction, with 70%-80% of these losses occurring in the piston-cylinder system, particularly in the piston rings. By improving the lubrication and surface texture of these components, engine performance can be enhanced, leading to reduced fuel consumption and longer engine life.

Historically, techniques such as vibrorolling, abrasive machining, and chemical etching have been used to improve surface textures, but these methods often result in inconsistent results. Laser surface texturing (LST) offers a better alternative by creating more uniform surface patterns with greater control. The nanosecond laser, with its 100 nanosecond pulse duration and 527-nanometer wavelength, is a cost-effective and industrially feasible alternative to more expensive laser technologies like the femtosecond laser.

The ARCI researchers have demonstrated the success of this method by creating micro-groove and micro-crosshatch patterns on gray cast iron surfaces, commonly used in critical engine components. These textures can trap lubricants and wear debris, improve hydrodynamic lubrication, and expose graphite flakes that act as solid lubricants, further reducing friction and wear.

Tribological tests conducted with a ball-on-disk tribometer confirmed significant reductions in friction and improved wear resistance. These advances are not limited to IC engines; the potential applications span various industries, offering a sustainable and cost-effective solution for improving component performance across the automotive and manufacturing sectors.

The development of nanosecond laser surface texturing by ARCI marks a significant advancement in tribological engineering, paving the way for more efficient and reliable industrial applications focused on friction and wear management.