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As the automotive industry shifts toward hybrid and alternative drive concepts like electromobility, it remains vital to continuously improve internal combustion technology. Internal combustion applications represent the largest portion of transportation technologies. Continuous development and improvement of passenger car engines focus on reducing emission by weight reduction and enhanced efficiency. To gain a competitive advantage in present and future engines, Mercedes-Benz AG developed the innovative NANOSLIDE Ò technology that uses thermal spray technology, i.e., twin wire arc spray, to coat the internal diameter of cylinder bores. Computational fluid dynamics (CFD) simulation is utilized to investigate the complex gas flow in the cylinder bore of the crankcase during the coating process. Extensively experiments are performed and analyzed to compare the results with the quantitative analysis in order to enhance the properties of the cylinder coating. The combination of simulation and coating experiments led to the development of uniform distributed layer adhesion strength throughout the length of the cylinder bore.

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