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Application process, and performance in engine dynamometer and high mileage vehicle fleet durability tests of Plasmaspray coated bore aluminum block engines are discussed. Fuel economy, oil consumption, power and wear data for Ford 4.6L-V8 aluminum block engines utilizing very low cost iron/iron oxide base coatings, and stainless steel/BN solid film lubricant Plasmasprayed coatings are presented. Test results from Ford's 100 hour Piston & Gasket Engine Dynamometer Durability Tests, and Fleet Vehicle Durability Tests show ring/bore wear reductions of more than 40% relative to production cast iron bore systems with Oil Economy averaging more than 13,600 km/l (8000 mi/qt).

An investigation describing engine friction reduction benefits attainable via the introduction of Solid Film Lubricants to piston skirts is presented. Ford II-25 thermoset and II-25 waterborne molybdenum disulfide based solid film lubricants were shown through single cylinder motored engine experiments, to produce piston system friction reductions of 12 to 17% at 1500 rpm. Further tests undertaken in fired engine dynamometer studies, on a 1.91 1-4 CVH engine, demonstrated total engine friction reductions of 6% at W.O.T. conditions. The reduced engine friction resulted in lowering BSFC at 850 rpm by 3 to 4%. Tests conducted by Powertrain Operations confirmed durability. II-25 thermoset was selected for production implementation on all new Ford engines starting from model year 1995.

Feasibility of wall-flow diesel exhaust filter trap particulate aftertreatment emission control systems to meet the U.S. Federal, CARB, and EC passenger car standards for 1997/2003 and beyond for the 1360 kg (3000 lb.) EAO (Ford European Automotive Operations) 1.8 liter Sierra Turbo-Diesel passenger car is investigated. Plain and Pd catalyzed monolith wall flow diesel particulate traps are examined using Phillips No. 2 diesel fuel (Reference Standard), low sulfur (0.05% S) diesel fuel and an ultra-low sulfur (0.001% S) diesel fuel. Comparisons are made with baseline FTP75 and Highway exhaust emissions and Federal and CARB mandated particulate standards for 1997 and 2003. Effectiveness of catalyzed traps, plain traps, copper octoate trap regeneration fuel additive, and fuel sulfur content on the particulate emissions is determined.