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.

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.