Driving Automotive Improvements by Reducing Weight, Fuel and Emissions

Faced with a unique challenge with its MX-30 e-SKYACTIV R-EV project, the car maker aimed to optimize the rotary unit of this model by transitioning from cast iron to aluminum, seeking to reduce weight by 15 kg while maintaining durability and performance. Oerlikon‘s advanced thermal spray solution using HVOF technology played a pivotal role in Mazda‘s transformation.

Oerlikon's SUMEBore™ offers a powder-based thermal spray cylinder bore coating solution to address several challenges: enhancing fuel economy through low friction coatings and lighter engines, increasing corrosion and wear resistance, and reducing oil consumption by up to 82%. This plasma coating solution package is customizable to your application needs and seamlessly integrates into your production process. With over 20 years of proven market success, it's trusted by leading OEMs like Volkswagen and Audi, with Porsche achieving a remarkable ten-fold improvement in wear resistance in their new V8 turbo engine compared to non-coated surfaces.

Coatings are pivotal in enabling the use of lightweight materials in electric cars, boosting their energy efficiency. For instance, a 10% lighter electric vehicle can extend its range by 5-7%, equivalent to running an extra leg of a marathon. By reducing vehicle weight, coatings contribute significantly to improving energy efficiency and overall performance. Ultimately, this synergy between coatings and lightweight materials is driving a transformative shift in the automotive industry towards more sustainable and efficient mobility solutions.

With Oerlikon's advanced coatings, corrosion, friction and wear can be reduced for over 100 car parts. The resulting fuel efficiency and improved durability of light metals means manufacturers can build smaller engines. When manufacturers adopt a comprehensive approach to component coating, they can cut fuel consumption by 2% to 4%, reduce oil consumption by 30%, and cut engine block weight by 12%.