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In this paper, we will demonstrate the effectiveness and usefulness of a new class of superlow-friction carbon films in alleviating the wear and scuffing problems associated with the use of low-sulfur diesel fuels in fuel delivery systems of advanced diesel engines. Specifically, using a well-established diesel fuel lubricity test machine, we will show that with the use of very thin (1 μm thick), super lubricious carbon films, one can restore lubricity and virtually eliminate scuffing and potential wear failures that can occur in low-sulfur, super-clean, and zero-sulfur (Fischer-Tropsch) diesel fuels. Test results from our study raise the prospect for using such carbon coatings to solve problems associated with the use of low-sulfur diesel fuels and high injection pressures in future engines.

An increase in engine and vehicle efficiency usually requires an increase in the severity of contact at the interfaces of many critical components. Examples of such components include piston rings and cylinder liners in the engine, gears in the transmission and axle, bearings, etc. These components are oil-lubricated and require enhancement of their tribological performance. Argonne National Laboratory (ANL) recently developed a carbon-based coating with very low friction and wear properties. These near-frictionless-carbon (NFC) coatings have potential for application in various engine components for performance enhancement. This paper presents our study of the tribological performance of NFC-coated steel surfaces when lubricated with fully formulated and basestock synthetic oils. The NFC coatings reduced both the friction and wear of lubricated steel surfaces. The effect of the coating was much more pronounced in tests with basestock oil.