SUMEBore

High-Performance Cylinder Bore Coatings

Thermal Spray
Don’t Compromise
on Your Targets SUMEBore coating technology helps you achieve your
emission reduction goals and meet strict regulations

Do you want to reduce friction, wear, corrosion, oil consumption, fuel consumption, Improve fuel economy up to 4% with optimized coating solutions
emissions and weight while increasing engine performance? Eliminate the cast iron cylinder liner to reduce engine weight and
fuel consumption, and improve heat transfer
Oerlikon Metco’s SUMEBore™ is a powder-based thermal spray cylinder bore coat- Reduce oil consumption up to 82% thanks to superior surface
ing solution that meets key challenges of internal combustion engine manufacturers properties
in automotive, marine, aero and power generation industries. SUMEBore can be Eliminate the use of heavy metal alloys, such as chromium, in the entire
tailored to meet the performance targets of your engine design. product life cycle with Metco 1017A coating material

Improve fuel economy with low friction coatings and lighter, more compact engines
Increase corrosion and wear resistance for consistent long-term performance
Reduce oil consumption by up to 82%
Tailored SUMEBore coatings enable you to max out
Meet specific coating requirements where other technologies fail
engine performance and ensure reliable operation

Increase corrosion resistance and achieve up to 10 times better wear

rates for peak performance throughout the entire vehicle lifetime
Improve the cold start performance of hybrid engines
Support fuel-efficient technology with cylinder deactivation (ACT)
Enable use of alternative fuel types
Increase heat dissipation resulting in improved anti-knock properties
Boost engine performance up to 4% with optimized cylinder liner
and piston ring coatings

Take Your The SUMEBore coating solution is flexible and customizable,

Coating Process moving beyond the limitations of other coating technologies

 asily coat complex geometrical components such as compact

E

to a New Level
blocks and small cylinder diameters
Rework used engine blocks to save costs and improve sustainability
Utilize our know-how and experience that takes you from the
development stage to mass production — wherever you are located

Boost your productivity and benefit from improvements that significantly

reduce the cost per bore with the RotaPlasma™ HS1 gun handling system.

Increase the flexibility and performance of plasma sprayed coatings

at a competitive cost per bore

 chieve up to 4-times faster coating process speeds compared

A
to the original RotaPlasma

All but eliminate downtime from gun changeover and significantly

reduce maintenance requirements
The SUMEBore Tailor the Process
Solution Package to Your Requirements
Over the past 20 years, Oerlikon Metco has engaged extensively with leading OEMs and invested significant The SUMEBore materials toolbox is based on modular powder The powder-based nature of SUMEBore materials is
resources to develop functional coating solutions for combustion engine cylinders. The SUMEBore solution chemistries that can address all issues that occur in a combustion significantly more flexible for customizable coatings.
package, which can be tailored to different applications and customer requirements, includes: engine cylinder such as friction, scuffing, corrosion and abrasive wear. The range of materials extends from fully metallic
(mainly iron-based) to metal matrix composites (MMC),
 Development and prototyping capabilities and ultimately to pure ceramics.
 The coating material (customized powder)
 The coating system Metals Blends
 The necessary know-how including the rights to use all relevant intellectual property to carry out the SUMEBore process
Material type Heavy Metal-Free Alloy Low Alloy Carbon Steel Chrome Steel + Oxide Ceramic

Serial Production Process Stability ++++ ++++ +++

The Atmospheric Plasma Environmental Safety

Friction Reduction
++++
++
++
++
++
+++

Spray Coating Process Wear Resistance

Corrosion Protection
++
+
++
+
+++
++++

SUMEBore Powders Metco 1017A XPT 512 F2071

Casting & Machining + = basic, ++ = advanced, +++ = high, ++++ = very high

Surface Activation SUMEBore is a powder-based atmospheric

plasma spray coating process for cylinder bore
surfaces. The SUMEBore solution package can 100 µm 100 µm
be easily integrated into your production
setup from prototype to mass production. Metallographic section of environmentally-friendly, heavy Metallographic section of XPT 512 — a low alloyed
metal-free Metco 1017A that provides the same high carbon steel material with over two decades of proven
performance and value as XPT 512. serial production — applied on a mechanically activated
Complete coating solution with SUMEBore bore surface (as-sprayed).
Spray Process
Together with key industry partners, Oerlikon Metco
offers the industrialization of the entire coating
process, from surface activation to the application Enhanced Hydrodynamic Behavior
of the plasma coating through the final machining.
The plasma coatings are “mirror finished” by
Conventionally plateau honed Diamond honed surface of a
surface diamond honing. The oil is retained in the small, SUMEBore coating
open pores on the surface which leads to
Efficient production systems
enhanced hydrodynamic behavior and friction
Machining / Honing reduction potential. Although SUMEBore coatings
A SUMEBore engineered system is customized to meet are wear-resistant, the homogeneous distribution
your requirements for part size, production quantities and of these pores throughout the coating guarantees
variability. consistent performance throughout the life of the
engine as new pores are exposed as the coating
wears.
Atmospheric Plasma Significant Reduction
Spray vs. Wire Spray in Process Costs
Powder-based atmospheric plasma spray (APS) always had one key advantage over wire Oerlikon Metco is continuously working on improving the productivity of the SUMEBore
spray: the ability to choose from a broad range of materials and to combine several mate- solution package. Combining process efficiency improvements and material cost reductions
rials to impart multiple benefits on the substrate. These benefits include friction reduction, have lowered the cost per cylinder bore by more than 50 % compared to the baseline costs
wear and corrosion resistance. Today, APS outperforms wire spray in the most relevant of of 2014.
process criteria at a comparable cost per bore.

Atmospheric Cost per bore comparison 2014 Cost per bore comparison 2018
Process Criteria Wire Spray
Plasma Spray
Cost per bore Cost per bore Basis for calculation:
Materials choice 100,000 L4 blocks / year
100 100
APS offers a broad selection of materials and allows Ø = 74 mm (2.9 in)
for customizable coatings including metal powders, 80 80
Depth = 130 mm (5.1 in)
metal matrix composites and ceramics. excluding honing costs
60 60

Thermal influence 40 40

A high thermal influence can be detrimental to the

20 20
substrate. Both technologies have a low thermal
influence on the substrate.
0 0
Wire spray SUMEBore Wire spray SUMEBore

Coating quality
Thanks to the defined powder particle size,
APS ensures reduced coating variability with
better distribution of pores and oxides.

Process reliability
Both processes have demonstrated robust and Now with a cost per bore comparable to wire spray technology, all the
reliable performance in the mass production of benefits of powder-based atmospheric plasma spray solutions are available
leading manufacturers. at no extra cost.

 enefit from a mature and reliable process that has been tested and implemented by
B
Coating roughness and thickness numerous leading engine manufacturers including Volkswagen, BRP-Rotax, Cosworth and
APS significantly reduces as-sprayed coating Yamaha Motors.
roughness and requires less coating to be applied Use the benefits of metals and ceramics to combine friction and wear reduction with
resulting in reduced honing requirements. corrosion resistance in one coating.
Eliminate costly masking thanks to new developments that minimize overspray and material
residues.
Process costs Realize additional cost savings thanks to significantly reduced coating thickness and thus
Increased efficiency of the APS process combined reduced honing efforts.
with reduced material production costs have resulted Save a costly, time-consuming step in the coating process because APS requires no pre-
in a comparable cost per bore for both technologies. heating of the engine block.
SUMEBore Cylinder Bore Coatings
Advanced Technology Solutions and Services

Perfect solutions through optimum materials and innovative technologies

Oerlikon Metco is a global leader in surface engineering Oerlikon Metco provides a comprehensive manufacturing,
solutions and services offering: distribution and service network, catering to aviation, power
generation, automotive and other strategic growth industries.
 broad range of thermal spray, laser cladding and other
A
advanced surface technology equipment To take control of your surface engineering challenges,
Integrated systems and materials contact your Oerlikon Metco sales office, visit our web site at
Specialized coating and surface enhancement services www.oerlikon.com/metco
Manufactured components for turbine, automotive and
other industries or e-mail us at
Customer support services info.metco@oerlikon.com

About Oerlikon Metco

Oerlikon Metco enhances surfaces that bring benefits to customers through a
uniquely broad range of surface t­echnologies, equipment, materials, services,
specialized machining services and components. The surface techno­logies such as
Thermal Spray and Laser Cladding improve the performance a ­ nd ­increase efficiency
and reliability. Oerlikon Metco serves industries such as aviation, power generation,
automotive, oil & gas, industrial and other specialized markets and operates a
dynamically growing network of more than 50 sites in EMEA, Americas and Asia
Pacific. Oerlikon Metco, together with Oerlikon Balzers and Oerlikon AM, b ­ elongs to
the Surface Solutions Segment of the Switzerland-­based Oerlikon Group.

Information is subject to change without prior notice.

BRO-0028.2 – SUMEBore
© 2021 Oerlikon Metco