Press Release - Federal Mogul's Innovative IROX Bearing
Shell Design Enables Fuel Consumption and CO2 Reduction by Increasing
Reliability of High-Output, Hybrid and Stop-Start Engines
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Federal Mogul's Innovative IROXTM Bearing Shell Design Enables Fuel
Consumption and CO2 Reduction by Increasing Reliability of High-Output,
Hybrid and Stop-Start Engines
New IROXTM coating increases bearing durability by more than five times
Southfield, Michigan, March 23, 2010... Federal-Mogul Corporation
has expanded the performance capabilities of engine
bearings by developing an innovative polymer coated bearing shell that
can reduce fuel consumption and CO2 emissions by withstanding mechanical
loads produced by heavily boosted engines. Called IROX(tm), the new
technology addresses the lubrication challenges associated with frequent
engine re-starts found in hybrid and other future stop-start engines by
protecting both the crankshaft and the bearing shells from damage where
metal-to-metal contact would otherwise occur. It is estimated that the
IROX bearing overlay can help increase the life of crankshafts and
bearing shells by more than five times in more extreme applications,
such as direct-injected engines and engines with stop-start systems.
"The drive for increased engine efficiency is placing demands on
crankshaft bearings that require new designs and materials
applications," said Michel Prefot, Federal-Mogul's vice president,
technology and innovation, bearings. "Satisfactory lubrication requires
an adequate oil film between the bearing shell and the crankshaft to
keep the surfaces apart. Efforts to reduce fuel consumption and CO2
output is pushing engine design towards reducing oil film thickness and
significantly increasing the number of starts, which is where bearings
are most vulnerable. Federal-Mogul's new IROX bearing overlay
technology overcomes many of the most challenging wear-related issues
that will be faced by a majority of new generation engines."
(more)
As engines are downsized but maintain their output through
turbo-charging, the specific loads on the bearings increase. When
hybrids operate in electric mode or when drivetrains using
stop-start strategies switch off the engine, the crankshaft speed drops
to zero. Without rotation, the crankshaft settles into contact with the
bearing shells and the oil pump stops providing lubrication, allowing
metal-to-metal contact and causing wear when the engine restarts.
The lubrication conditions at start up are very different from those
that exist during high-speed, high-load operation. While solid
lubricants or dry bearing materials are effective at preventing
metal-to-metal contact at low running speeds, these conventional
solutions are not suited to higher speeds, which require journal
bearings with a generous lubricant supply. Federal-Mogul's new system
combines the best features of both these established technologies by
introducing a polymer coating for traditional metallic bearing shells,
integrated with solid lubricants and wear inhibitors to produce a
cost-effective, robust and production-ready solution. Extensive
development has led to the identification and optimization of a number
of key parameters, such as layer thicknesses, substrate material
specification, resin binder properties, curing conditions and functional
additive specifications, and a number of patents on the technology.
The IROX bearings have an overlay that is a PAI (PolyAmideImide) polymer
resin binder containing a number of additives dispersed throughout the
matrix. These additives provide a variety of properties to the finished
coating, such as wear resistance, mechanical strength, thermal
conductivity and embeddability (the ability to safely envelop loose
abrasive particles).
Test results have shown a dramatic improvement in life compared to both
conventional shell materials and state-of-the-art competitors. "Typical
bearings with aluminium overlays show significant wear after 100,000
stop-start cycles," said Prefot. "However, the new generation of engine
systems require 250,000 to 300,000 cycles, so the durability challenge
has been raised. Bearings with the IROX overlay can meet the demands of
repeated starting; in comparison tests where conventional aluminium
overlays showed 100 microns of wear and lead-free bronze showed up to 50
microns, our shells still looked like new with a measurable wear of just
a few microns."
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Another advantage of the new Federal-Mogul bearings is improved
conformability, which has the effect of increasing the bearing surface
area and hence increasing the load capacity. This means specific loading
can be increased through the use of boosting, and low viscosity oils can
be used by vehicle manufacturers (to improve fuel economy) without
increasing risk of engine seizure, both important benefits in the
development of low emission engines.
Because of superior IROX bearing overlay durability, vehicle
manufacturers also can now consider utilizing cost-effective nodular
iron crankshafts, thus mitigating the need for an expensive, forged
steel crank. This compatibility also eliminates the need for hardening
of the pins and journals on the crankshafts. As vehicle manufacturers
struggle to offset the cost burden of increasingly sophisticated engine
systems such as turbocharging and direct injection, any reduction in
base component specification is welcome.
IROX-overlay bearings are the latest addition to Federal-Mogul's
comprehensive portfolio of lead-free bearings products. "The IROX
bearing overlay is an excellent example of how we're continuing to
strengthen our position as the world's leading engine and transmission
bearings manufacturer," said Gerard Chochoy, senior vice president,
Powertrain Sealing and Bearings. "We see excellent opportunities to
displace conventional bearings in many automotive and other applications
with the IROX overlay."
"We believe our IROX overlay is a game-changing technology," concluded
Prefot. "Increasing fuel economy and reducing CO2 emissions, while
meeting the durability challenge of start-stop and hybrid applications
supports the trend of highly-loaded downsized engines while enabling the
use of more cost-effective crankshaft materials." Pilot manufacture of
the new shells has been underway since 2005, and full-scale production
is scheduled for next year.
About Federal-Mogul
Federal-Mogul Corporation is a leading global supplier of powertrain and
safety technologies, serving the world's foremost original equipment
manufacturers of automotive, light commercial, heavy-duty, agricultural,
marine, rail, off-road and industrial vehicles, as well as the worldwide
aftermarket. The company's leading technology and innovation, lean
manufacturing expertise, as well as marketing and distribution deliver
world-class products, brands and services with
quality excellence at a competitive cost. Federal-Mogul is focused on
its sustainable global profitable growth strategy, creating value and
satisfaction for its customers, shareholders and employees.
Federal-Mogul was founded in Detroit in 1899. The company is
headquartered in Southfield, Michigan, and employs nearly 39,000 people
in 33 countries. Visit the company's Web site at
<http://www.federalmogul.com> www.federalmogul.com.
Forward-Looking Statements
Statements contained in this press release, which are not historical
fact, constitute "Forward-Looking Statements." Actual results may differ
materially due to numerous important factors that are described in
Federal-Mogul's most recent report to the SEC on Form 10-K, which may be
revised or supplemented in subsequent reports to the SEC on Forms 10-Q
and 8-K. Such factors include, among others, the cost and timing of
implementing restructuring actions, the Company's ability to generate
cost savings or manufacturing efficiencies to offset or exceed
contractually or competitively required price reductions or price
reductions to obtain new business, conditions in the automotive
industry, and certain global and regional economic conditions.
Federal-Mogul does not intend or assume any obligation to update any
forward-looking statement to reflect events or circumstances after the
date of this press release.
# # #
Press Contact
Martyn Roberts or Richard Gotch
Market Engineering, 43-44 North Bar, Banbury, OX16 0TH, United Kingdom
+44 (0)1295 277050
martyn.roberts@m-eng.com
richard.gotch@m-eng.com
Images
High resolution images are available from Martyn Roberts:
martyn.roberts@m-eng.com or call +44
(0) 1295 277050.
Image_7293-2_rev.jpg
The IROX(tm) bearing overlay can help increase the life of crankshafts
and bearing shells by more than five times in more extreme applications,
such as direct-injected engines and engines with stop-start systems.
A480 3MPa
Conventional bearing shell after 20,000 stop-start cycles
IROXTM coated shell after 100,000 stop-start cycles
Competitor shells after 500hr engine test
IROXTM coated shells after 500hr engine test
