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Autocraft showcases PTWA Technology at Engine Expo 2014

27-03-2015

Autocraft Drivetrain Solutions made its world launch of its PTWA Cylinder Bore Coating capability to this year’s visitors of Engine Expo at the Stuttgart Messe in Germany. Visitors to the stand saw how PTWA (Plasma Transferred Wire Arc) technology…

Autocraft Drivetrain Solutions made its world launch of its PTWA Cylinder Bore Coating capability to this year’s visitors of Engine Expo at the Stuttgart Messe in Germany. Visitors to the stand saw how PTWA (Plasma Transferred Wire Arc) technology is being used in the recovery of cylinder blocks to remanufacture engines, through the coating of cylinder bores. Autocraft’s brand new £2.3m PTWA manufacturing cell in its facility in Grantham, UK, makes it the first engine remanufacturer to hold such technology.

Autocraft is seeking to use its PTWA expertise to attract new customers and to further develop its PTWA investment for the production of new cylinder blocks for the very latest generation of fuel efficient engines, as OEMs seek to achieve Euro 6 emissions standards and even lower CO2 emissions.

PTWA is a major step-change in engine technology. Traditionally, when engine blocks are remanufactured they are over-bored to have either cylinder liners fitted or have oversized pistons installed. However, engine technology is moving to more compact and lighter cylinder blocks. This limits the ability to re-use or remanufacture cylinder blocks using these traditional techniques. The latest generation of engines have cylinder wall thicknesses that are not sufficient to over-bore or fit liners, so this is where PTWA technology provides the solution. Without PTWA, the ability to remanufacture engine blocks in the future will be extremely limited.

Commercial and engineering director Mike Hague-Morgan explains further “PTWA is certainly the future for engine block recovery. The thickness of the cylinder walls is no longer an issue for Autocraft because our PTWA machine sprays the cylinder bores with a thin layer of molten metal in a rotary motion down the bore, returning it back to a standard size. The cylinder bores are then honed on our latest and fully controllable CNC honing machines, before being fully cleaned and passed back to the remanufacturing process to have standard pistons fitted.”

“PTWA is becoming so popular, OEMs are now using the PTWA technology in the cylinder blocks of new vehicles because there are many benefits. Blocks are being developed that do not use cast iron liners. Future engines will have an all aluminium block construction, representing a significant weight reduction for the manufacturer. This results in not only a cost saving, but also leads to better oil and fuel efficiency and contributes to Euro 6 compliance. Autocraft is in a unique position, being the only engine remanufacturer to have this capability to recover all types of cylinder blocks, and also produce new, all aluminium linerless blocks. ”

Autocraft’s PTWA machine is versatile and flexible, and can be fixtured up for many varieties and sizes of cylinder blocks. Autocraft has the capacity to fully coat over 80,000 cylinder bores per annum.

Autocraft has developed this technology over the past 10 years in conjunction with Ford, Flame Spray and GTV. Autocraft has the licence to use the patented process without restriction for all its customers in both new and remanufactured engines, and is seeking opportunities to provide its capability and capacity beyond its existing customer base.

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