In a development that has significant implications for the massive automobile sector in India as well as other industries, scientists have come up with a low-cost nano-technology-based laser surface coating that increases lubrication of the moving parts in an engine, thereby enhancing performance and fuel efficiency.
Called nanosecond laser surface texturing, this technology is applicable to internal combustion engines that run on fossil fuel. Though these engines form the largest component of the automobile industry, a major disadvantage of such engines is the friction and wear between moving parts, which causes enormous energy loss resulting in low fuel economy.
To address the problem, researchers at the International Advanced Research Centre for Powder Metallurgy and New Materials (ARCI), came up with a solution to enhance the lubrication between critical moving parts within the engine, which include piston rings and cylinder liners.
Nanosecond laser surface texturing can produce high-quality surface textures rather cost-effectively as compared to other contemporary methods being used, making it a more practical solution for industrial applications.
Earlier surface texturing technologies such as vibrorolling, abrasive machining, reactive ion etching, lithography, abrasive jet machining and chemical etching lack uniformity in surface patterns, thus decreasing effectiveness. On the other hand, laser texturing provides better control over the shape and size of the surface textures, whether dimples, grooves, or any other patterns, with a fast processing rate.
Nearly 50 per cent of the energy in internal combustion engines is lost due to thermal and frictional dissipation. Out of this, 70-80 per cent loss occurs in components such as piston rings, compression rings and oil control rings. This is influenced by the geometry and texture of the surfaces in contact.
Textured surfaces can act as reservoirs for lubricants, allowing oil to be delivered more effectively to the contact zones where friction occurs and as well as trap debris, thereby reducing abrasive friction. These surfaces also have the potential to improve hydrodynamic lubrication, which occurs when a full film of lubricant separates two surfaces, thus minimizing contact and reducing wear.
“In tests conducted under different conditions, the laser-textured surface demonstrated high improvement in reducing friction and raising wear resistance,” a statement issued by the Ministry of Science and Technology on Friday read. “These results were not limited to the combustion engine. Optimising laser textured surfaces holds immense potential for improving component performance in general from various industries. Reduced friction and wear by this technology allows more efficient, sustainable, and cost-effective solutions for industries ranging from the automotive industry to manufacturing,” the statement added.
As far as the automobile industry is concerned, India figures among the top five nations in the world. According to the Society of Indian Automobile Manufacturers, 2.84 crore vehicles across all segments were produced in 2023-24. India is the largest producer of two-wheelers, third largest of trucks and fourth largest producer of cars, with the industry poised to grow significantly over the next few years.
