MoS2 Gear Coating: Reduce Friction & Extend Gear Life
Category
Dry Film Lubrication coating on gears
Project Type
Monthly Production
Product/ Service Details
Revolutionizing Drivetrains: MoS2 Coating for High-Efficiency Gears
In the pursuit of automotive excellence, reducing internal friction is the key to unlocking better fuel economy and longer range. Hardai ARMND Engineering Solutions introduces specialized Molybdenum Disulfide (MoS2) coating for gearbox and differential gears—a breakthrough that allows manufacturers to rethink traditional lubrication strategies.
From electric vehicles (EVs) to heavy-duty trucks and buses, our coating technology serves as a permanent, secondary lubrication system that enhances performance where oil alone falls short.
Oil Churning and Transmission Loss
Currently, automotive gearboxes and differentials are filled with high volumes of gear oil to ensure all contact surfaces stay lubricated. However, this traditional approach faces several critical issues:
- Oil Churning Phenomenon: At high speeds, the gears must "plow" through a large volume of oil. This creates significant fluid resistance, known as churning loss, which consumes energy and reduces overall transmission efficiency.
- Viscosity Dynamics: Over time and through thousands of thermal cycles, gear oil degrades. Its viscosity changes, and it can become a source of resistance rather than a facilitator of motion, leading to sluggish performance.
- The Weight Penalty: Larger oil reservoirs add weight to the vehicle—a critical concern for EV range and IC engine fuel standards.
- The Risk of Reduced Oil: Simply lowering the oil level to reduce churning is dangerous, as it risks "dry starts" or localized overheating at the gear mesh points.
MoS2 as a Secondary Lubrication System
MoS_2 coating by Hardai ARMND Engineering creates a "Solid Lubrication Shield" directly on the gear teeth. This layer acts as a fail-safe and an efficiency booster that works in tandem with reduced oil volumes.
- Enabling Lower Oil Quantities: By applying a high-performance MoS2 dry film, the gears are no longer solely dependent on the oil bath for surface protection. This allows automotive engineers to safely reduce the gearbox and differential oil levels. With less oil to "churn" through, the gears move more freely, directly increasing the mechanical efficiency of the drivetrain.
- Protection Against Boundary Lubrication: During start-up or extreme load conditions, the oil film can break down (boundary lubrication). Our MoS2 coating provides an immediate, low-friction sliding surface that prevents metal-to-metal contact, protecting the gear flanks from scuffing and pitting even when the oil hasn't yet reached the contact point.
- Compensating for Oil Aging: As gearbox oil ages and its lubricating properties fluctuate, the MoS2 layer remains constant. It provides a stable, secondary lubrication source that ensures the gear transmission efficiency stays high throughout the entire service interval of the vehicle.
Applications Across the Automotive Sector
Our coating solutions are designed for mass production, catering to the diverse needs of the modern transport industry:
- Electric Vehicles (EVs): In EVs, where gearboxes operate at extremely high RPMs, MoS2 is essential to minimize friction losses and maximize battery range.
- Internal Combustion (IC) Cars: Reduces CO2 emissions by improving the "fuel-to-wheel" energy transfer.
- Heavy Trucks and Buses: Protects massive differential gears under high torque loads, extending maintenance intervals and reducing the total cost of ownership.
Hardai ARMND Engineering
Hardai ARMND Engineering Solutionsspecializes in the high-volume application of MoS2 coatings. Our automated process ensures that every gear—from the smallest planet gear to the largest ring gear—receives a uniform, tenacious coating that meets strict automotive tolerances.
By integrating our coating into your production line, you can achieve a "leaner" gearbox design that uses less oil, generates less heat, and delivers superior power transmission.
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