Methods For Providing High-Surface Area Coatings To Mitigate Hydrocarbon Deposits On Engine And Powertrain Components

Abstract

Provided are methods related to preventing hydrocarbon residue buildup in engine, exhaust-gas-system or powertrain components. Prevention is achieved by applying coating of a mixed metal oxide via a suspension plasma spray.

1 . A method of applying a coating to an engine, exhaust-gas-system or powertrain component, the method comprising suspension plasma spraying a coating a mixed metal oxide onto an engine, exhaust-gas-system or powertrain component, wherein the coating contains a component that oxidizes hydrocarbons. 
     
     
         2 . The method of  claim 1 , wherein the component that oxidizes hydrocarbons prevents residue buildup. 
     
     
         3 . The method of  claim 2 , wherein the engine, exhaust-gas-system or powertrain component is selected from the group consisting of turbocharger, valve, piston, piston fireland, firedeck, compressor housing, intake port, injection nozzle, shroud, swirl generator, combustion chamber and combinations thereof. 
     
     
         4 . The method of  claim 3 , wherein a surface of the engine, exhaust-gas-system or powertrain component that is prone to residue buildup is sprayed. 
     
     
         5 . The method of  claim 4 , wherein the coating comprises a mixed metal oxide, the mixed metal oxide comprising at least two metals selected from the group consisting of Al, Ti, Ce, Pr, La, Y, Nd, Mn and combinations thereof. 
     
     
         6 . The method of  claim 5 , wherein the coating further comprises a precious metal. 
     
     
         7 . The method of  claim 6 , wherein the precious metal comprises Pd. 
     
     
         8 . The method of  claim 1 , wherein the coating is catalytically active to remove carbonization residue. 
     
     
         9 . A method of applying a coating to an engine, exhaust-gas-system or powertrain component, the method comprising suspension plasma spraying a coating onto an engine, exhaust-gas-system or powertrain component, wherein the coating comprises a mixed metal oxide comprising at least two metals selected from the group consisting of Al, Ti, Ce, Pr, La, Y, Nd, Mn, Zr and combinations thereof. 
     
     
         10 . The method of  claim 9 , wherein the coating is catalytically active for the oxidation of hydrocarbons. 
     
     
         11 . The method of  claim 9 , wherein the engine, exhaust-gas-system or powertrain component is selected from the group consisting of turbocharger, valve, piston, piston fireland, firedeck, compressor housing, intake port, injection nozzle, combustion chamber and combinations thereof. 
     
     
         12 . The method of  claim 11 , wherein a surface of the engine, exhaust-gas-system or powertrain component that is prone to residue buildup is sprayed. 
     
     
         13 . A method of applying a coating to an engine, exhaust-gas-system or powertrain component, the method comprising:
 forming a suspension by dispersing mixed metal oxide particles in a liquid;   feeding and injecting the suspension into a plasma torch or plume; and   plasma spraying of the suspension towards the surface of an engine, exhaust-gas-system or powertrain component.   
     
     
         14 . The method of  claim 13 , wherein the suspension plasma is sprayed onto a surface of the engine, exhaust-gas-system or powertrain component that is prone to residue buildup. 
     
     
         15 . The method of  claim 13 , wherein the mixed metal oxide comprises at least two metals selected from the group consisting of Al, Ti, Ce, Pr, La, Y, Nd, Mn, Zr and combinations thereof. 
     
     
         16 . The method of  claim 13 , wherein forming a suspension further comprises dispersing a precious metal in the liquid. 
     
     
         17 . The method of  claim 16 , wherein the precious metal comprises Pd.