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Actuator Shaft with Enhanced Bushing Surfaces for an EGR assembly

Problem:

This actuator shaft for an EGR assembly was being made from a high cost, solid T-800 alloy. The expensive shaft failed from fractures induced in assembly and in-service. A more robust design was needed to resist damage and failure, while still retaining the benefits of the T-800 alloy: specifically high temperature wear and oxidation resistance, as well as low friction, anti-galling properties.

Actuator Shaft With Enhanced Bushing Surfaces for an EGR Assembly

Solution:

A more robust, durable design was created from a solid, 400 series stainless steel shaft, with HVOF coating of a T-800 alloy applied only in the 2 regions that required the special material properties. These 2 regions mate with high performance bushings.

Results:

Successful integration of long-life, heat resistant coating which eliminated the assembly damage problem and provided the required performance in-service at a lower overall cost. The new shaft with coating integrated into the bushing areas provides easy assembly and reliable performance in the demanding service environment.

Value Statement:

Precision Coatings helped improve the product design and continues provide reliable, FULL-SERVICE complete component supply and high volume production of 10,000-80,000 annually.

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Actuator Shaft with Enhanced Bushing Surfaces for an EGR assembly Specifications

Product Description Emissions control actuator shaft with high temperature, wear resistant, low friction coating to prevent galling and oxidation.
Capabilities /Processes/Services
  • Design Engineering /Product Development
  • Complete Component Supply
  • HOVF Spray Coating
  • Machining of basic shaft
  • Centerless Grinding
  • High Volume Production
Coating Solution Benefits (Coating Properties)
  • High Temperature Oxidation Resistance
  • Abrasion Resistance
  • Wear Resistance
  • Anti-Galling
  • Low Friction
Overall Part Dimensions
  • O.D.: Ø .4750”
  • OD Face Length: 6”
  • Coating Length: (2) 1.5” long areas on main OD
  • Coating thickness .008”-.012”
Tolerances
  • +/- .0003” on Final OD dimension
  • .4 micrometer Ra finish or less
Hardness 55-60 Rc
Temperature Rating 1300°F
Material Used
  • Coating similar to T800 alloy - Tribaloy®
  • 400 series stainless steel part substrate
Max Material Finish .4 micrometer Ra finish or less
Coating Color Gray/Silver
Estimated Part Weight .20 lbs
Industry for Use Diesel Engine Emissions Control
Quantity 10,000 – 80,000 per year
Delivery Time Ongoing to meet production demand
Standards Met Customer Defined Specifications

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