FriktionTek's Ceramic Coating Process
Part surface before treatment
Initially, the metal friction surfaces consist of microscopic relief peaks and recesses (known as micro-abrasions). The recesses are packed with contaminants from various by- products of oil and additive decomposition (Fig.1).
During operation, loading occurs to brings these surfaces together. The microscopic peaks in the metal surface rupture the films formed by the oil and additives, making direct contact with one another and increase friction. As a result, these microscopic peaks break and add metal particulates to the oil (which also act as contaminants).
When the peaks break, microscopic flashes occur. These flashes increase heat and oxidize oils and additives, creating more contaminants (Fig.2).At each pass, more microscopic peaks break, adding more contaminants to the oil.
Microscopic peaks grind FriktionTek's ceramic particles down from micro- to nano-scale
Compared with the microscopic peaks and recesses FriktionTek's ceramic particles appear quite large (Fig.3).
The microscopic peaks grind the ceramic-metal particles to nano-scale. During this grinding process, the microscopic peaks continue to break due to contact with each other and contact with our particles. This causes the microscopic flashes intensify. At these microscopic peak contact points, it causes high temperature flashes (900-1200ºC) . This heat is sufficient to create the catalyst which causes FriktionTek's ceramic particles to fuse with the metal particulates which will "grow" the new crystals of the ceramic-metal (cermet) surface.
The remaining metal surface quickly transfers the heat away from the contact zones, allowing the crystals to cool enough to harden (Fig.4).These microscopic peaks form the first areas of a ceramic-metal (cermet) protective coating.
Removing contaminants from the part surface
The catalyst which creates the cermet surface combined with special structure of our nano-scale cermet particles are better capable of cleaning the microscopic peaks and recesses than detergents. FriktionTek® will clean the microscopic peaks and recesses of practically all contaminants (including additives, friction modifiers, metal conditioners) – typically within an hour of normal operation.
As the microscopic peaks and recesses are cleared, a large quantity of the contaminants previously packed on the part surface are being released into the oil . In the case of heavy contamination cases, the oil should be changed at 1,250 miles.
Our cermet particles pack tightly into microscopic recesses of the metal surface
Our cermet particles are in tight contact with each other and the surface layer metal. This is provided by:
1. Absolute ability of our nano particles to fuse with metal particles and each other;
2. Orientation of the particles in the direction of the least mechanical resistance.
On the surface, microscopic electromagnetic fields orient our nano particles in the direction of least resistance. The new cermet crystals begin to penetrate the crystal lattice of the part surface to bond on a molecular level with the metal. At the same time, the microscopic peaks pack the cermet particles on contact. This is called work-hardening. As a result, the new cermet surface becomes harder than the original metal surface (Fig.5).
Growing the new cermet layer
FriktionTek® gives more efficient wear protection than any standard lubricant or additives can provide. Since friction is reduced, the heat released at the part surface is dramatically reduced and the oil (although it is contaminated until your next oil change), is more effective.
Due to work-hardening, the cermet nano particles bond completely with the metal. During normal operation, the energy from friction continues to create the catalyst necessary to "grow" new cermet crystals with a more spatial crystal lattice (Fig.6).
These new cermet crystals start to "lift" over the part surface and make up for wear. The remaining ceramic-metal particles accumulate on the surface and level it off. The thickness of the cermet layer is proportional to the amount of friction energy and quantity of the cermet particles hardened into the microscopic recesses–so parts with heavy wear will create a thicker surface if a second (Fig.7).
