Pulsed Waterjet Roughening of Cast Iron and Aluminum Alloy for Automotive Engine Remanufacturing with Plasma Transferred Wire Arc Coating
Bibliographic record
Abstract
This study utilized the high-pressure pulsed waterjet process and paired it with the plasma transferred wire arc technology to develop a novel technique to remanufacture damaged engine cylinder bores. The objective of this research was to eliminate the need for expensive bond-coats such as Ni-Al by optimizing the surface roughness profile of the substrate to provide acceptable mechanical bonding between the coating and the substrate. In this study, a high chrome stainless steel wire (Metcoloy #2) was plasma spray coated on a wide range of pulsed waterjet roughened surface profiles generated on grey cast iron and cast aluminum A380 alloy, the two most common engine materials. The pulsed waterjet greatly increased the adhesion strength between the substrates and the Metcoloy #2 coating. The increase in adhesion strength is a result of the formation of favorable mechanical anchoring points. Optimal pulsed waterjet parameters were determined to avoid the production of a copious roughness profile which resulted in a coating that mirrored the roughened surface profile. Additionally, if the roughness profile produced by the pulsed waterjet was insignificant the coating was removed in its entirety during detachment-based failure.
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How this classification was reachedexpand
Full frame distilled prediction
Teacher imitationNot calibrated prevalence, not ground truth. Human validation pending. Learned from the 10,348 direct Codex labels and 10,348 direct Gemma labels. Candidate is the union of thresholded teacher heads; consensus is their intersection. These outputs are machine_predicted_unvalidated and are not human labels or direct frontier model labels.
Codex and Gemma teacher scores by category
| Category | Codex | Gemma |
|---|---|---|
| Metaresearch | 0.000 | 0.000 |
| Meta-epidemiology (narrow) | 0.000 | 0.000 |
| Meta-epidemiology (broad) | 0.000 | 0.000 |
| Bibliometrics | 0.000 | 0.000 |
| Science and technology studies | 0.000 | 0.000 |
| Scholarly communication | 0.000 | 0.000 |
| Open science | 0.000 | 0.000 |
| Research integrity | 0.000 | 0.000 |
| Insufficient payload (model declined to judge) | 0.000 | 0.000 |
Machine scores (provisional)
The two teacher heads of the student model, read on this work. A score orders the frame for review; it never asserts a category, and the validation status ships verbatim with every row.
Baseline scores from an immature model (maturity gate not passed, 7 training rounds). Scores rank; they never assert a category.
score_only:v0-immature-baseline · verbatim from the scoring run: score_only means the number may rank works, and no category label ships from itClassification
machine, unvalidatedMachine predicted; a candidate call from one teacher head, not a consensus.
How this classification was reached, model by model and score by score, is at the end of the page under "How this classification was reached".