журнал для КР по англ
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Aero-engines |
Efficient transport |
Renewable fuels |
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Solutions for reducing |
Sulzer coatings are |
Development of second- |
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CO2 emissions |
always present |
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EDITORIAL
Sulzer’s technology— key for transportation
Dear technology experts, customers, and partners,
Did you know that a quarter of the worldwide annual primary energy consumption is needed for transportation alone? Economic globalization has led to an increasing need for the transportation of goods over longer distances from the producer to the consumer. In addition, people now travel increased distances to work and in their spare time. These requirements have risen substantially in the last few decades.
This issue of the Sulzer Technical Review (STR) focuses on Sulzer’s solutions for current and future requirements concerning fuel consumption, pollutant emissions, durability, maintenance, and renewable fuel production. Sulzer products are present at many levels—both visible and invisible to the end user.
You will learn, for example, how specialists at Sulzer Metco develop and produce innovative honeycomb seals to increase the efficiency of aircraft engines. A further article surveys Sulzer Metco’s surface refinement of individual automotive components. This treatment increases durability, lowers friction, and is environment friendly. Contrary to first-generation biofuels, second-generation biofuels are made from waste biomass. Sulzer Pumps’ and Sulzer Chemtech’s solutions are crucial for the future production of these environmental friendly fuels. Further, Sulzer Turbo Services presents its high-speed balancing facilities in Houston and Winterthur.
I hope you enjoy reading about these and other innovative developments of the Sulzer divisions and Sulzer Innotec.
Sincerely yours,
Ton Büchner
CEO Sulzer
Sulzer today
The Sulzer brothers laid the foundations of today's company 175 year ago in Winterthur, Switzerland. Sulzer is active in the fields of machinery, plant construction, and surface technology in more than 120 locations around the world. Its divisions are global leaders in their respective markets, including the oil and gas sector, the hydrocarbon processing industry, power generation, pulp and paper, aviation, and the automotive industry. Sulzer employs a total of 12,500 professionals who develop innovative new technical solutions. These products and services enable Sulzer's customers to achieve sustained improvements in their competitive positions.
www.sulzer.com
Sulzer Pumps
Sulzer Pumps offers a variety of centrifugal pumps, ranging from custom-built models to standardized series. The division's marketleading position reflects its research and development activities relating to processoriented materials as well as its reliable service. It serves customers in the oil and gas, hydrocarbon processing, pulp and paper, power generation, water distribution and treatment sectors, as well as other specialized areas. www.sulzerpumps.com
Sulzer Metco
Sulzer Metco specializes in thermal-spray and thin-film processes for surface technology applications. The division coats and enhances surfaces, produces materials and equipment, and develops machining processes for special components. Its customers are active in the aviation and automotive industries, the power generation segment, and other specialized markets.
www.sulzermetco.com
Sulzer Chemtech
Sulzer Chemtech is the market leader in the fields of process technology, separation columns, static mixing, and cartridge technologies. The division has sales, engineering, production, and customer service facilities throughout the world that enable it to meet the needs of its customers in the oil and gas, chemical, petrochemical and plastics industries. www.sulzerchemtech.com
Sulzer Turbo Services
Sulzer Turbo Services is the largest independent provider of repair and maintenance services for thermal turbomachinery and other rotating equipment. The division also manufactures and sells replacement parts for gas and steam turbines and compressors. Its customers operate in the oil and gas, power generation, and other specialized industrial sectors. www.sulzerts.com
Sulzer Innotec
The research and development unit supports the development projects of Sulzer's own divisions as well as projects of industrial companies around the world by providing contract research and special technical services. Sulzer Innotec has considerable expertise in materials engineering, surface engineering, fluid technology and medical technology, as well as in the field of mechanics. Its core competencies in the area of contract research also focus on these traditional disciplines. www.sulzerinnotec.com
2 | Sulzer Technical Review 4/2009
CONTENTS
4 News
Exhibitions, Events
Transportation
6
8
11
Requested by the airlines
Manufacturing environmentally friendly aero engines
High tech for transportation
Optimized surfaces for a more efficient transport
Emissions reduction
How coatings make a difference
14 For a more sustainable world
Advanced renewable fuels
17 Sulzer analogy
Animals also discovered the wheel
Panorama
18 High-speed balancing
An investment with good returns
22 New mist elimination technology
Solutions for drying natural gas
25 Sulzer history
A history of surface technology
26 Beyond measurements
Numerical analysis of a RotaPlasma™ spray process
29
30
Sulzer world
Welcome to Sulzer Pumps in Brazil
Interview
Darayus Pardivala, Sulzer Turbo Services
31 Imprint
On the cover:
Starter gear with diamond-like carbon coating from Sulzer Metco.
Sulzer Technical Review 4/2009 | 3
Exhibitions, Events
December 8–10, 2009, Las Vegas, USA
Power-Gen International 09 www.power-gen.com
Information for Sulzer Turbo Service: Ashley Englebert Phone +1 713 567 2702
ashley.englebert@sulzer.com Information for Sulzer Pumps: Jim Willis Phone +1 318 742 9617 jim.willis@sulzer.com
December 8–10, 2009, Las Vegas, USA
Nuclear Power International 09 www.nuclearpowerinternational.com Information for Sulzer Pumps: Jim Willis Phone +1 318 742 9617 jim.willis@sulzer.com
December 10–13, 2009, New Orleans, USA
NGWA 09 www.ngwa.org
Information for Sulzer Pumps: Jim Willis Phone +1 318 742 9617 jim.willis@sulzer.com
January 26–28, 2010, Bismark, USA
EGC Energy Generation Conference 2010 www.bismarckstate.edu
Information for Sulzer Pumps: Jim Willis Phone +1 318 742 9617 jim.willis@sulzer.com
February 4–7, 2010, Istanbul, Turkey
WIN World of Industry 2010 www.win-fair.com
Information for Sulzer Metco: Karin Gehrig Phone +41 56 618 81 61 karin.gehrig@sulzer.com
March 8–10, 2010, Brisbane, Australia
Ozwater 2010 www.ozwater10.com.au
Information for Sulzer Pumps: Jonathan Fullford Phone +61 3 9826 3472 jonathan.fullford@sulzer.com
March 9–12, 2010, Gothenburg, Sweden
International Industrial Maintenance 2010 www.maintain-europe.com
Information for Sulzer Pumps: Kerstin Sallermo Phone +46 11 24 99 06 kerstin.sallermo@sulzer.com
March 23–26, 2010, Beijing, China
Nuclear Industry China NIC 2010 www.nic-expo.net
Information for Sulzer Pumps: Hongyi Liu Phone +86 10 6510 1777 hongyi.liu@sulzer.com
March 24–26, 2010, Perth, Australia
Australasian Oil & Gas Exhibition and Conference 2010 www.aogexpo.com.au
Information for Sulzer Pumps: Bob Beckett Phone +61 8 9309 1171 robert.beckett@sulzer.com
Honor for SUMEBore™ technology
Sulzer Metco has been nominated as one of nine finalists for the Swiss Technology Award. The Swiss Technology Award has been the leading technology prize in Switzerland for more
than 20 years. This prize is awarded for enhanced innovations in all areas.
The Sulzer MetcoAutomotive Venture division has
established three business models based on technology used to coat cylinder bore surfaces for different market segments. The aim of these models is to offer customers complete solutions for their automotive needs. Sulzer Metco used one of these business models to apply for the
Swiss Technology Award 2009. This technology offers a complete solution for the coating of cylinder surfaces on combustion engines. The solution package consists of the coating machine, the coating material, and our specific know-how. This coating reduces emissions as well as oil and fuel consumption.
SUMEBore™ coatings are already used by two European and one Asian engine manufacturer. In North America, diesel locomotives are being tested with this coating.
Sulzer Pumps is “TOP AREVA
Supplier”
Sulzer Pumps received the prestigious award for customer partnership—the “TOP AREVA Supplier” award—from AREVA president, Anne Lauvergeon.
“This award emphasizes the values that Sulzer stands for and pursues in every customer relationship. With attractive and innovative solutions, we want to support our customers and make them more competitive”, said Michael Streicher, Managing Director at Sulzer Pumpen (Deutschland) GmbH. Mr. Streicher accepted the award at a ceremony held in Berlin on July, 1st 2009.
AREVA created the award program to give greater visibility to the quality of its relationships with suppliers and to promote those that support AREVA in its growth. To be recognized as a “TOP AREVA Supplier”, a company is judged by performance in 25 criteria, including quality, competitiveness, and innovation, as well as long-term partnership. Other decisive criteria include sustainability in development, environmental protection, and safety.
In her remarks at the ceremony, Ms. Lauvergeon said the “TOP AREVA Supplier” award is to acknowledge and, at the same time, encourage deepening
relationships, strength, and reliability in the competitive global market. “A company that fulfills all 25 criteria is more than just a supplier—such a company is a real partner.” The 2009 awards mark the first time AREVA has recognized its suppliers in Germany with this seal of quality.
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NEWS
Future Sulzer solutions through ideas lab
For this year's celebration of “175 years Experience Sulzer”, a special event—the Sulzer Idea Lab for the Future—was organized in cooperation with the Swiss Federal Institute of Technology (ETH) in Zurich. This idea generation event took place on November 4, 2009, and focused on alternative energy technologies, such as concentrated solar thermal power, wind power, second-generation biofuels, and carbon capture and storage. Twenty participants from Sulzer and about 15
professors and scientific talents held an intensive brainstorming session on possible opportunities for Sulzer. The most attractive ideas will be pursued in the near future. This event further strengthens the partnership between the ETH Zurich and Sulzer, and further dialog will be held on a regular basis.
Sulzer Pumps expands service network
Being close to its customers is key to Sulzer Pumps’ commitment to service. With more than 60 service centers worldwide, Sulzer Pumps operates one of the industry’s most extensive service networks, which supports operators of Sulzer and non-Sulzer pumping equipment. It continually adapts this network to provide a complete range of customer support services that draw on Sulzer Pumps’ technical expertise and industry experience. Services include field service, repairs, spare parts, and retrofits, as well as maintenance and operation agreements. Sulzer Pumps actively seeks and assesses new opportunities to increase its customer support services
worldwide. In recent years, Sulzer Pumps has opened new service centers that expand its service capabilities in strategic markets:
•The flagship project is the new facility in Abu Dhabi, UAE, where the focus is on serving customers engaged in the oil, power, and water segments in the Gulf states. The facility also houses Sulzer Pumps’ regional sales and project management teams.
•In the industrial city of Bitterfeld, Germany, Sulzer Pumps opened a service center to support the heavy use of pumps by the local chemicals, plastics, and aluminum industries.
•The new service center in Volta Redonda, Brazil, is located at a customer site to service the needs of approximately 900 pumps operating in this major steel-manufacturing region.
•Sulzer Pumps has successfully expanded its service engineering presence in Cape Town, South Africa, to include workshop facilities.
•A new service center has also been opened in Shanghai, China, to serve the Chinese power, oil and gas, and HPI markets.
Accreditations to analytics expanded
Sulzer Innotec has expanded its accreditations to plastic analytics and asbestos analytics. The assessors of the Swiss Accreditation Service (SAS)— the federal accreditation office for laboratories, inspection bodies, and certification bodies according to international standards—carefully examined the laboratories, confronted the employees with fictive situations, tested the efficiency of the processes, and audited the reliability of the equipment. This certification guarantees customers standardized and comprehensible operational processes as
well as reliable, prime-quality, and on-time results.
With the expansion of the accreditation of the plastic analytics laboratory—for which recently significant investments were made—Sulzer Innotec is actively seeking seals of quality accreditations for all relevant activities. These measures help Sulzer to offer its customers a wide range of accredited measurement services from one source.
Sulzer Technical Review 4/2009 | 5
TRANSPORTATION
Manufacturing environmentally friendly aero engines
Requested by the airlines
In the last few decades, airlines have started demanding more efficient engines for their fleet. The future of air traffic is highly dependent on environmental and economic factors, such as fuel consumption, fuel prices, alternative fuels, airport noise limitations, and CO2 emissions. Sulzer Metco offers solutions that meet the needs of the aero industry.
ll original equipment manufacturing (OEM) companies like GE, Rolls Royce, Snecma, and Pratt
& Whitney are responding to this challenge by developing state-of-the art engines. They are employing advanced light materials and coatings, thin wall castings, and other complex technologies in order to improve thermal efficiency, increase propulsive efficiency, and reduce weight and noise.
A supplier to most OEMs
As a supplier to almost all engine OEMs, Sulzer Metco contributes to this challenge by offering and adapting its expertise and manufacturing capabilities. Currently, Sulzer Metco is involved in several high-tech civil aero engine programs, such as the Trent 900, GP7000, Trent 1000, Trent XWB, BR725, PW1200, PW1500, and SaM146/TP400. These engines power different classes of civil airplanes.
Sulzer Eldim, part of the Sulzer Metco division, consists of three entities located in three European countries. Sulzer
Engine and corresponding airplane
Trent 900, GP7000 |
Airbus 380 |
Trent 1000 |
Boeing 787 |
Trent XWB |
Airbus 350 |
BR725 |
Gulfstream G650 |
PW1200 |
Mitsubishi Regional Jet |
PW1500 |
Bombardier C series |
SaM146 |
Sukhoi Superjet 100 |
V2500 |
Airbus 320 series |
CFM56 (upgrade) |
Boeing 737 |
Neomet products: typical honeycombs.
Eldim (NL), in Lomm, Netherlands, is specialized in the manufacturing of labyrinth air seals and industrial gas turbine (IGT) airfoil drilling; Neomet Ltd, in Stockport, United Kingdom, is specialized in the manufacturing of honeycombs , an essential component of a labyrinth air seal; and Sulzer Eldim (HU), in Debrecen, Hungary, is specialized in manufacturing sheet metal details, nozzle guide vane inserts, and baffles and offers a best-cost supplier option to our
customers. Currently, Sulzer Eldim (HU) is involved in the production of the V2500 nozzle guide vane inserts.
Know-how and manufacturing experience
Labyrinth air seals are used in aero gas turbines to reduce airflow leakage at stator/rotor tips. The ability to design and manufacture seals with less weight and tighter tolerances will significantly contribute to the overall performance of
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TRANSPORTATION
Seal test rig.
the engine. Weight restrictions and tighter tolerance schemes are driving the manufacturability of a part to its limits. For example, machining a thin wall casting cost-effectively without deforming the shape of the component is a challenge for any supplier and, consequently, also for the customer. For that reason, the OEMs frequently use Sulzer Eldim’s accumulated know-how and manufacturing experience in the predesign phase of their products. In this co-design phase, customers can still adjust their final definition of the labyrinth seal to favor any of the above-mentioned requirements. During any development and engineering phase, it may become evident that the first design does not meet the required performance targets, and thus, changes may be needed to overcome this deficiency. Sulzer Eldim has often proven that know-how and manufacturing experience contributes to a more favorable approach in the design phase and therefore, ultimately, to a more successful solution.
Developing a new labyrinth seal
In addition to its direct work with OEMs, Sulzer Eldim has participated in a joint collaboration and initiative of the Dutch Aero Engine Cluster (DAEC) to develop a new labyrinth seal concept that will improve gas turbine efficiency. This development was undertaken in cooperation with DutchAero, Atkins Nedtech,
NLR, and VGT. Different seal concepts were evaluated against the following criteria: interface, performance, weight, manufacturability, costs, reliability and maintenance, design life, assembly, safety, technical risks, intellectual property, regulatory, tool development, and standard work. During the evaluation process, a staggered labyrinth seal was selected. The selected concept was optimized for seal performance using detailed computational fluid dynamics (CFD) analysis. The performance improvement was demonstrated experimentally against a base line stepped labyrinth seal in a specially designed seal test rig at the National Aerospace Laboratory . The results were above expectations. A 42% performance improvement with a two-knife-edge staggered labyrinth seal could be measured against a two-knife-edge stepped base line labyrinth seal . Based on these
New staggered seal—CFD analysis
results, the DAEC is currently in the process of defining a new development program with the goal of joining Snecma's green engine platform. Sulzer’s contribution to this program will be its manufacturing know-how and experience of seal components.
Sulzer Metco, through its Sulzer Eldim facilities, produces critical components for aero engines, using expert design and conventional and non-conventional machining capabilities. Through its collaborations, Sulzer Eldim contributes in the development of environmentally friendly aero engines for the global market.
10 mm
Rotor concept: Staggered honeycomb seal.
Wim Walsweer
Sulzer Eldim (NL) B.V. Spikweien 24
5943 AD Lomm Netherlands
Phone +31 77 473 1919 wim.walsweer@sulzer.com
Base line seal—CFD analysis
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Sulzer Technical Review 4/2009 | 7
TRANSPORTATION
Optimized surfaces for a more efficient transport
High tech for transportation
Sulzer is still known as a former manufacturer of large diesel engines for ships. Even today, former Sulzer patents are still used in the construction of fuel-saving and reliable large engines. But that is history. Nevertheless, the surface technology of the Sulzer companies is still decisively important for the transportation of today and tomorrow.
t is not always obvious where coat- |
highly developed plasma and gas nitrid- |
ings have been applied. But they are |
ing processes, the IONIT OX procedure |
Ia decisive factor for the function, serv- |
should be mentioned in particular. In this |
ice life, performance and efficiency of a |
sensor-controlled gas nitrocarburizing |
component. This can also be extended to |
process, a wear-resistant Epsilon-nitride |
all transportation vehicles; whether on |
layer is created, followed by a plasma |
land, sea, or air. Sulzer coatings are |
activation process at a lower temperature |
always present. The type of coating |
that stabilizes the Epsilon phase and pro- |
applied depends on the area in which |
vides crystallization seeds for the subse- |
an engine is operating. A wide range |
quent post-oxidation. The result is an |
of surface treatments are used for high- |
extremely adhesive, fine crystalline— |
performance engines, in particular, in |
and thereby dense—magnetite layer at |
order to guarantee the necessary |
the surface, which, in addition to offering |
performance. |
very good corrosion protection, also |
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reduces the coefficient of friction. The |
Environment friendly and affordable |
range of applications for the IONIT OX |
Coatings help protect the environment. |
procedure thereby extends from corro- |
All the coatings systems used by Sulzer |
sion-threatened components, through |
Metaplas are thereby free of Cr-VI, and |
hydraulic systems and up to safety com- |
do not release any environmentally |
ponents subject to high mechanical |
harmful substances, even during the |
stresses. |
coating process itself. They are ideally |
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suited for the substitution for environ- |
Nitriding and PVD coatings |
mentally harmful coating systems, help |
In addition to high-performance coatings |
to reduce weight, and make it possible to |
for cutting, the palette of classical PVD |
substitute more expensive, high-alloyed |
coatings ranges from tools for the form- |
materials, thereby making the system |
ing and plastic technology, through high |
more economical. The processes used by |
quality tools, up to components for |
Sulzer Metaplas include various nitrid- |
engine technology. In the component sec- |
ing processes and physical vapor deposi- |
tor, expensive, difficult-to-machine mate- |
tion (PVD) coatings. In addition to the |
rials are substituted by affordable materi- |
als that are adapted to the high loads by an appropriate combination treatment of plasma-nitriding and PVD coating. The customer profits from improved performance combined with lower costs. Diamond-like carbon coatings (DLC coatings), which have a wide application area thanks to their low coefficient of friction and their extraordinary range of variants, play a special role in transportation.
If we consider the “heart” of every vehicle, the engine, a wide variety of coating applications can be found. Crankshafts are nitrided to improve their endurance. Camshafts and tappets are also nitrided, and are provided with lowwear coating for further optimization. The use of DLC-coated hydro-tappets has provided a performance increase of 4% for a well-known motorcycle manu- facturer—without any further modifications, i.e., purely as a result of the reduced friction. Piston rings receive wearand friction-reducing PVD coatings that last longer than the life of the car. Plasma sprayed coatings enable cylinders to run for longer and, in some cases, make it possible to operate without cylinder liners. Valves are nitrided and coated in order to minimize the friction between the
8 | Sulzer Technical Review 4/2009 |
4279 |
Starter gear with diamond-like carbon coating.
valve shaft and guide. Valve springs can withstand higher speeds thanks to the residual compressive stresses induced by the nitriding. The nitriding of cylinder linings, crankshafts, piston heads and valves has already become standard in many areas of the large diesel engine sector.
Without coating—unrealizable
If we extend our consideration to ancillary units, it is the components of the modern common-rail injection systems that especially profit from high-tech coatings, or would not be able to be realized at all without coatings.As a result of alternative fuels, injection pump covers that were previously electroplated are now successfully protected against corrosion with IONIT OX. DLC coatings of Type a-C:H-Me bring unimagined benefits, for example, for starter gears . Through their microductile behavior, they not only successfully prevent the formation of pitting, but also significantly reduce the electric power consumption through the reduced friction. As a result, not only smaller and lighter starter motors will be possible in the future, butsmaller batteries can also be fitted. In addition to the required durability, vehicle gearboxes
above all require a light construction, low manufacturing costs and a high ease of operation. The designs are comparatively complicated and often have to be adapted for higher torques and performance. Numerous coatings can be found in the power transmission. In order to reduce vibrations, the clutch plate is fitted with high-load torsion damping springs, which are given higher dynamic strength by a nitriding similar to that used for the valve springs. The selector shaft is a perfect example of an optimized design, as it is built using frictionand laserwelding procedures and individual components from different materials produced in various manufacturing processes. Therefore, the surfaces must be correspondingly protected from wear and corrosion, as well as having a coefficient of friction that is as low as possible. This variety of demands can be fulfilled through an optimized IONIT OX process, so that a considerable cost saving can be achieved compared with the alternative treatments and coatings.
TRANSPORTATION
Ensuring wear protection
Disk carriers are manufactured in forming processes in which the material is mainly selected based on forming considerations. The high stresses applied to the disk carriers by the “beads” of the clutch disk would lead to rapid wear. The clutch disk and the disk carrier are therefore mostly plasma nitrocarburized in order to ensure the required wear protection and to avoid any cold welding.
The synchronizer ring is normally carried out as a double synchronizer. Due to the more complex geometry of the synchronizer rings, the latter are manufactured through either the cold forming of construction steel or as sintered components. Nowadays, the gearing and straps are preferably protected from wear by plasma nitriding. Many of them are nitrided by Sulzer Metaplas, and are then coated with carbon friction coatings by Sulzer Friction Systems . The synchronizer bodies are almost exclusively made from sinter materials, and obtain their wear protection through a plasma
Synchronizer rings are often protected against wear by plasma nitriding or plasma nitrocarburizing.
Sulzer Technical Review 4/2009 | 9
TRANSPORTATION
nitrocarburizing process. The differential |
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pinion shaft on which the bevel gears in |
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the differential gearbox directly run is |
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rather inconspicuous. In addition to the |
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high stress, fitting tolerances of 10µm |
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steel and well-coordinated mechanical |
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processing, |
the IONIT OX |
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alternative to other, more expensive, |
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processes. |
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Wear and corrosion have to be avoided |
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in the running gear. Over the last ten |
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years, the ball studs treated by Sulzer |
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Metaplas |
have helped to make worn |
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and fractured ball-and-socket joints |
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obsolete at almost all well-known Euro- |
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pean vehicle manufacturers. In addition |
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to the excellent corrosion protection, the |
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good friction behavior between the |
ment of hard-chrome-plated brake |
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IONIT OX treated ball surface and the |
pistons. Covering plates and brake discs |
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POM bush in the joint should be high- |
have already been successfully tested. |
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lighted. Approximately 60–70 |
million |
The range of applications can be |
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ball studs a year are now treated world- |
expanded even further, whether consid- |
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wide using this process. |
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ering windshield wiper axes, selector |
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, gas springs, hydraulics, or |
From the brakes to the windshield |
even the tools themselves. Regardless of |
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wiper axle |
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whether cutting, forming, or plastic pro- |
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The nitriding know-how of Sulzer |
cessing, Sulzer Metaplas helps to carry |
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Metaplas is also in demand in the brake |
out the manufacturing of vehicles in a |
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area, and is used as standard for the wear- |
more |
economic and environmentally |
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proof and |
corrosion-resistant |
replace- |
friendly way through its surface treat- |
Overview of vehicle components coated by Sulzer.
ments. Together with the OEMs or their suppliers, a team of experts develops a suitable coating system, so that our mobility can also be retained in the future.
Thomas Auf dem Brinke
Sulzer Metaplas GmbH
Am Böttcherberg 30–38
51427 Bergisch Gladbach Germany
Phone +49 2204 299 293 thomas.aufdembrinke@sulzer.com
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