A leap in high-pressure technology
November 2013 – The cleaning and deburring of workpieces by means of high-pressure water systems has been the state of the art for the manufacturing of engines and transmissions in the automotive industry for many years. As a global market and technology leader Dürr Ecoclean has developed this technology further and thus found entirely new applications with its EcoCBooster.
The EcoCBooster is a technology filed for patent by Dürr. It allows for increasing the power of a water jet to five times its initial kinetic energy. The EcoCBooster leads to considerable savings in investment and energy costs, in particular compared to applications in the ultra-high pressure range of up to 3,000 bar. A good example is the roughening of cylinder tracks in crankcases.
Due to their enhanced durability, liners (inserts) made of steel or gray iron are often cast into the cylinder bores. Following mechanical machining they are honed until they have reached the required dimension and surface quality. The heavy weight of these liners and the larger dimensions of the crankcases are a disadvantage.
The aim of downsizing engines is to increase performance and reduce emissions while minimizing engine capacity. The cylinder bore is coated with very thin protective layers instead of cast liners. These layers are applied onto the surface of the workpieces by thermal injection. To ensure sufficient adhesion, the surface within the bore must first be roughened. In our example, this is achieved by means of high-pressure water.
The benefits of high-pressure water jetting compared to other processes are as follows: It ensures very good adhesive tensile strength during the subsequent thermal coating, and there is no tool wear as would be the case with mechanical machining. At the same time, there is no need for cleaning after the roughening.
Processes previously used are based on a high-pressure water jet of at least 2,500 bar. Sometimes chemicals have to be added to the water to prevent oxidation of the roughened surface. The water then has to be thoroughly filtered, or fresh water must be used. This leads to a considerable increase in investment and operating costs. The EcoCBooster achieves very good surface cleaning results even at around 600 bar and without any extensive filtering.
The EcoCBooster can also be applied for example in high-pressure deburring, coating removal from workpieces, high-pressure paint removal, cutting or well development.Not only for the automotive industry, the EcoCBooster is a leap in high-pressure water jetting. Additional areas of application are found in medical technology and aircraft engine manufacturing. The delivery of the first pilot systems is already lying ahead.