Tribological Properties of Aluminum–Silicon Alloy Cylinder Liners Paired with DLC and CKS Piston Rings

With the increasing demand for energy conservation and emission reduction in the automotive industry, optimizing the performance of cylinder liner and piston ring pairs in engines has become crucial. Aluminum–silicon alloy cylinder liners, known for their lightweight and excellent thermal conductivity, have emerged as a new trend in cylinder liner materials. Given the relatively moderate hardness of Al-Si alloys, judicious selection of piston rings is imperative to ensure optimal performance. This study investigates the tribological properties of aluminum–silicon alloy cylinder liners paired with CKS and DLC piston rings. The surface morphology and hardness of the test materials were characterized, and reciprocating friction and wear tests were conducted, using a tribometer to simulate operating conditions. The friction coefficient and wear volume were used as indicators to evaluate the tribological properties of the piston rings. The results show that, when the aluminum–silicon alloy cylinder liner was paired with a DLC piston ring, the friction coefficient was 27.82% lower, and the wear volume of the cylinder liner was 83.52% lower, compared to pairing with a CKS piston ring. When paired with a CKS piston ring, wear was exacerbated because silicon particles were easily dislodged to form abrasive particles. This particle detachment is mainly caused by the collision between the fine ceramic particles embedded in the CKS coating and the silicon particles (≤5 μm) uniformly distributed in the Al-Si alloy cylinder liner during the sliding process. The DLC piston ring, containing both sp2 and sp3 hybridized carbon–carbon bonds, combined excellent lubrication properties with high hardness, resulting in minimal wear on both the cylinder liner and piston ring. Specifically, the DLC coating has a hardness of 2300 HV0.3, which is 2.42 times that of the CKS piston ring (950 HV0.3); the sp3-hybridized carbon in the DLC coating enhances its wear resistance to resist scratching from silicon particles in the cylinder liner, while the sp2-hybridized carbon forms a graphite-like transfer layer at the friction interface to reduce frictional resistance. In conclusion, the aluminum–silicon alloy cylinder liner paired with a DLC piston ring exhibits superior tribological properties. Selecting an appropriate piston ring can significantly enhance the tribological properties of the cylinder liner–piston ring pair, thereby extending the engine’s service life.