IC ENGINE

The Internal combustion engine is the most frequent types of drive used in motor vehicles. IC engines generate power by converting chemical energy bound in the fuel into heat and thus produced into mechanical work.

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Engine component weight

Component Cylinder head Cylinder block Crank shaft Flywheel Piston assembly Connecting rod assembly Injection equipment Starter+ alternator Other parts (each<2% of total) % of Total 8 34 9 11 2 1.8 4.2 10 20
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PISTON RING
PISTON RING IS A MOVING METALLIC SEAL USED IN AUTOMOTIVE ENGINES

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LOCATION OF RINGS

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PISTON RING LOCATION

Top compression 2nd compression

Upper Side rail

Nifflex-S Oil

Spacer Expander Lower Side rail

Piston

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PISTON RING ROLES

MOVING SEAL BETWEEN COMBUSTION CHAMBER & CRANK CASE HEAT TRANSFERING MEDIA LUBRICANT FILM METERING DEVICE SLIDING SUPPORT FOR PISTON

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RING NOMENCLATURE

INNER DIA RADIAL THICKNESS WIDTH

GAP END

OUTER DIA

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RING TYPES Groove Position

TOP COMPRESSION RINGS SEAL

SECOND COMPRESSION RINGS OIL CONTROL RINGS

SEAL & OIL SCRAPPING

OIL SCRAPPING

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RING TYPES - Material

STAINLESS STEEL RINGS GREY CAST IRON RINGS SPHEROIDAL GRAPHITE IRON RINGS

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TYPES OF STEELS
Low alloy steels Martensitic stainless steels Austenitic stainless steels

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SR10 (Steel Rolled ) [IP 208]

Used for compression rings Low alloy steel Higher hardness Poor corrosion resistance
C Si Mn P < 0.035 S < 0.04 Cr Hardness Tensile

0.50 / 0.60 1.20 / 1.60 0.50 / 0.80

0.50 / 0.80 R30N 65 / 72 < 1450 MPa

Composition Units are in %

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SR34 [IP 215A]

Used for compression rings & side rails 17% Cr. Martensitic stainless steel Good wear & scuff resistance Superior corrosion resistance Tougher steel
C Si Mn P < 0.04 S < 0.04 Cr Mo V Hardness Tensile 0.80 / 0.95 0.35 / 0.50 0.25 / 0.40 17.0 / 18.5 1.00 / 1.25 0.08 / 0.15 R30N 62 / 66 < 1200 MPa

Composition Units are in %

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SR35 [IP 221]

Used for compression rings & 2P oil rings 13% Cr. Martensitic stainless steel Good wear & scuff resistance Better corrosion resistance Harder than SR34
C Si Mn P < 0.03 S < 0.03 Cr Mo Hardness Tensile 0.60 / 0.70 0.25 / 0.50 0.25 / 0.50 13.0 / 14.0 0.20 / 0.40 R30N 59 / 63 < 1200 MPa

Composition Units are in %

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SR20 [IP 207]

Used for Nifflex-S spacer expanders 17% Cr. Austenitic stainless steel Good wear resistance Better corrosion resistance
C < 0.15 Si < 1.00 Mn 5.50 / 7.50 P < 0.06 S < 0.03 Cr Ni N < 0.25 Hardness Tensile 16.0 / 18.0 3.50 / 5.50 HV 380 / 490 < 1200 MPa

Composition Units are in %

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SR21 [IP 237]

Used for Nifflex-H spacer expanders 18% Cr. Austenitic stainless steel Good wear resistance Better corrosion resistance
C < 0.08 Si < 1.00 Mn < 2.00 P < 0.04 S < 0.03 Cr Ni Hardness Tensile 18.0 / 20.0 8.00 / 11.0 HV 230 / 290 < 735 MPa

Composition Units are in %

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SR02 [IP 211]

Used for Side rails Carbon steel Compatible coating : Cr plate OD/ID
C Si Mn P S Hardness Tensile

0.70 / 0.76 0.15 / 0.35 0.30 / 0.60

< 0.03

< 0.03

R30N 68~72

< 1600 MPa

Composition Units are in %

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Compression ring material-Cast Iron

IP 4 (AE 210) -STANDARD GREY CAST IRON TENSILE - 280 MPa IP 4A (AE 212) - LOW ALLOY GREY C.I TENSILE 300 MPa IP 3 (AE 222) - ALLOYED C.I TENSILE 410 MPa IP 16 (AE 226) -S.G IRON TENSILE 900 MPa IP 18 (AE222) -MALLEABLE CI. TENSILE 590 MPa En:150 GPa IP Rings Ltd En: 160 GPa En: 150 GPa En: 100 GPa En: 100 GPa

RING Surface coatings

INLAY MOLY COATED RINGS OVERLAY MOLY COATED RINGS HARD CHROME PLATED RINGS GAS NIRTRIDED RINGS

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Future Surface coatings of Rings

CHROME CERAMIC PVD [PHYSICAL VAPOUR DEPOSITION] HVOF [HIGH VELOCITY OXY FLAME] DLC [DIAMOND LIKE CARBON]

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PLASMA SPRAYING
Molybdenum alloys are sprayed on steel or CI surfaces by plasma spraying process either in-lay or over-lay. The sprayed surface will give the following benefits 1. Good wear resistance
INLAY MOLY

2. Superior Scuff resistance 3. Excellent Oil retention 4. High thermal stability 5. Better corrosion resistance
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OVERLAY MOLY

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HARD CHROME PLATING

Chromium will be deposited on to the periphery or All over the Steel & C.I Rings by electrolysis. 1. High wear resistance 2. Excellent fatigue strength 3. Economical Process 4. Less Scuff resistance

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GAS NITRIDING
Nascent Nitrogen reacts with steel surface and form nitrates of steel and diffusion layers.The Nitrides of steel form a layer of 1400 HV hardness which will give the following advantages. 1. High wear resistance 2. Good Scuff resistance 3. Excellent fatigue strength 4. Better finish 5. Economical and eco friendly Process
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CHARECTERISTICS OF SURFACE TREATMENT

HARDNESS THICKNESS HV 0.1 MICRONS 850 - 1000 100 MIN 300 - 550 1100 - 1200 620 - 710 600-750 1600 ~ 1800 200 MIN 60 MIN 10 MIN 200 MIN 20 MIN

COATING Hard Chrome Plating Moly Based Plasma Gas Nitriding Ceramic Coating HVOF Coating PVD DLC

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MATERIAL Vs COATING
COMPRESSION RING MAT. PROCESSES OIL RING MAT.

STEEL SG IRON ALLOY CAST IRON PLAIN CAST IRON

Nitriding Plasma Spray Flame Spray Periphery Cr Plating Allover-Cr Plating ID Cr Plating

STEEL 2 PIECE STEEL NIFFLEX

CAST IRON

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COATING COMPARISON
PROPERTY
WEAR RESISTANCE SCUFF RESISTANCE CORROSION RESISTANCE FATIGUE STRENGTH

NITRIDING
BEST GOOD GOOD BEST

MOLY
BETTER BEST BETTER GOOD

CHROME
GOOD BETTER BEST BETTER

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TOP RING - Cross sections

RECTANGULAR RINGS SINGLE SIDE WEDGE RINGS KEYSTONE GROUND RINGS

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TOP COMPRESSION RING

STEEL SPHEROIDAL GREY IRON MOLY COATED RING CHROME PLATED RING

PISTON

REGULAR

GAS NITRIDED RING

FUTURE

GAS NITRIDED RING / SINGLE WEDGE GAS NITRIDED RING / DOUBLE WEDGE

CYLINDER WALL

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2nd RING Cross sections

TAPER LAND COMP. RINGS TAPER & SIDE STEPPED RINGS TAPER & NAPIER STEP RINGS

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SECOND COMPRESSION
CAST IRON
CI MOLY COATED RING

PISTON

REGULAR

PLAIN CI RING CI CHROME PLATED RING

FUTURE CYLINDER WALL

STEEL CHROME PLATED RING STEEL MOLY COATED RING

NITRIDED STEEL RING

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OIL RING Cross sections

CONFORMABLE C.I. OIL RING 2PIECE STEEL OIL RING THREE PIECE STEEL OIL RING

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OIL CONTROL RING

CAST IRON STEEL REGULAR

PISTON

STEEL GAS NITRIDED

3 PIECE STEEL

STEEL CHROME PLATED

FUTURE

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CYLINDER WALL

2p Vs 3p OIL RINGS
CHARACTERISTICS
CONFORMABILITY MASS OF ASSEMBLY FRICTION BREAKAGE COST PER RING

2PIECE OIL
LESS HEAVY MORE HEAVY COSTLIER

3PIECE OIL
MORE LIGHT LESS NO CHEAP

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RING TYPES OD PROFILE

PARALLEL FACE RINGS BARREL FACED RINGS TAPER LAND RINGS NAPIER STEP CUT RINGS BEVEL LAND OIL RINGS

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PISTON RING PROPERTIES

OUTER DIA : OUTER DIAMETER OF A PISTON RING IS SAME AS THE BORE DIAMETER IN WHICH THE RING IS TO BE MATCHED

OUTER DIA

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PISTON RING PROPERTIES

CLOSED GAP THE CLEARANCE IN BETWEEN TWO GAP ENDS WHEN THE RING IS INSERTED INSIDE A GAUGE EQUAL TO BORE, IS CALLED AS CLOSED GAP
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CLOSED GAP

PISTON RING PROPERTIES

TANGENTIAL TENSION THE FORCE EXERTED BY THE RING ON THE CYLINDER WALL WHEN THE GAP ENDS ARE CLOSED TO A SPECIFIED GAP UNIT OF MEASURE : kgf
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PISTON RING PROPERTIES

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SURFACE TREATMENT
PISTON RINGS ARE PHOSPHATED TO GIVE A BLACK VELVETTE FINISH AS WELL AS TO PREVENT RUST MANGANESE / ZINC PHOSPHATING WILL GIVE A SPECIAL PROPERTY OF OIL RETENTION ON THE SURFACE OF RINGS SHELF LIFE AND INITIAL BEDDING-IN DURING ENGINE RUNNING WILL BE ENHANCED.
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2S ENGINE RING LAYOUT

TWO STROKE ENGINE USES ONLY TWO COMPRESSION RINGS SECOND RING IS BACKED WITH ONE PLATE EXPANDER TO OVER COME RING FLUTTER NOTCHED GAP ENDS TO AVOID RING BREAKING BECAUSE OF PORTS
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RING WITH PLATE EXPANDER

PLATE EXPANDERS ARE OF THIN STEEL SECTIONS WITH HUMPS

RING ASSEMBLY

PLATE EXPANDER

NOTCH

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4S ENGINE RING LAYOUT

TWO COMPRESSION RINGS AND ONE OIL CONTROL RING
T o p c o m p r e s s io n

2 n d c o m p r e s s io n

N if f le x - S O il

P is to n
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THREE PIECE NIFFLEX RING

TPR CONSISTS OF TWO SIDE RAILS AND ONE SPACER EXPANDER SANDWICHED INBETWEEN TWO TYPES OF TPR EXPANDERS: #1. NIFFLEX-H #2. NIFFLEX-S
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NIFFLEX-H EXPANDER
FOR THE AXIAL WIDTH LESS THAN 2.5mm H DESIGN IS GOOD
Tab seat angle Hump height Expander total width Step on side face Humpwidth

RING ASSEMBLY

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NIFFLEX-S EXPANDER
FOR THE AXIAL WIDTH MORE THAN 2.5mm S DESIGN IS GOOD
Tab seat angle Hump height Expander total width Step on side face Hump width

RING ASSEMBLY

Vent hole

Latch pin

Spring pad

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QUATILY RING PACK

NO BURR PROJECTION AT ANY EDGE FREE FROM RUST & PITTING HIGH WEAR RESISTANT MATERIAL GOOD SCUFF RESISTANCE COATING BETTER CONFORMABILITY INSIDE BORE LIGHT WEIGHT
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COMMON PROBLEMS
POWER / COMPRESSION LOSS BORE WEAR / SCORING MARKS HIGH LUB OIL CONSUMPTION HEAVY BLOW-BY FRICTIONAL LOSS RING BREAKAGE RING STICKING RING FLUTTER NOISE SCUFFING / MICRO WELDING
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COMPRESSION LOSS
EXCESS CLOSED GAP EXCESSIVE CLEARANCE BETWEEN PISTON GROOVE AND RING POOR CONFORMABLITY OF TOP RING WORN OUT PISTON RING

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BORE WEAR / SCORE MARKS

EXCESS HARDNESS OF COATING POOR SURFACE FINISH BURR FOLDING ON PERIPHERY

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HIGH LUB OIL CONSUMPTION

EXCESSIVE TOP RING GAP END CHAMFER POOR CONFORMABILITY TO BORE (LIGHT TIGHTNESS) LOW TANGENTIAL TENSION EXCESSIVE SIDE CLEARANCE WRONG ASSEMBLY OF TAPER LAND RING WORN OUT PISTON RINGS
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HEAVY BLOW-BY
ESCAPE OF FLUE GASES FROM PISTON CROWN TO CRANK CASE THROUGH RING SURFACE EXCESSIVE CLOSED GAPS EXCESS GAP END CHAMFERS EXCESS OD PERIPHERY CORNER CHAMFER POOR CONFORMABILITY TO BORE HIGHER BOTTOM SIDE LAND WIDTH OF THE COMPRESSION RINGS. EXCESSIVE BACK & SIDE CLEARANCES
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FRICTIONAL LOSSES
Others 23%

Oil Churning 5% Big end bearing 10% Valve train 6% Crank shaft 13%

Piston assy. 43%

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FRICTIONAL LOSS
HIGHER TANGENTIAL TENSION ROUGH SURFACE FINISH POOR OIL RETENTION ON SURFACE POOR GRADE OF MATERIAL
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RING BREAKAGE
POOR MATERIAL EXCESS HARDNESS BLOW HOLES, CRACKS ON SURFACE MORE D/T RATIO

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RING STICKING
INADEQUATE SIDE CLEARANCE POOR LUB OIL QUALITY HIGH LEVEL OF BLOW-BY SOOT FORMATION IN RING GROOVES TO OVERCOME RING STICKING PROBLEMS HALF / FULL KEYSTONE GROUND SIDE RINGS ARE USED
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SCUFFING
POOR COATING QUALITY OIL STARVATION HIGH TANGENTIAL TENSION INADEQUATE MATERIAL IMPROPER COATING

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PISTON RING SETS

Passenger cars

Jeeps & LCV

Trucks & Buses

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ABOUT VARIOUS COATING

SPECIAL CHROME PLATING: A special composite plating is under development so as to obtain higher scuff resistance than chrome plating. It has a layer of chromium with impregnated hard particles of the size of few microns

HIGH VELOCITY OXY FUEL FLAME SPRAY COATING: Flame velocity up to 2100 m/s, particle velocity up to 800 m/s (depending on HVOF system, fuel and material) Very high scuff resistance Very high bond strength compared to plasma coating Low porosity RAMIC COATING A kind of dip coating Ceramic material is coated on to the surface of the ring
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