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Ford using high-tech plasma coating process for recycling old engines

Ford is recycling old engines so they can be used again with the help of a special Ford-patented plasma coating technology. The process delivers a 50% reduction in CO2 emissions compared with producing a new engine.

We have taken a process that was originally developed to enhance performance models such as the all-new Ford Mustang Shelby GT 350R and used it to remanufacture engines that might otherwise be scrapped. It is just one example of how Ford is looking to reduce its environmental footprint through a range of innovative measures.

—Juergen Wesemann, manager, Vehicle Technologies and Materials, Ford Research and Advanced Engineering

The Plasma Transferred Wire Arc thermal spray process and other sustainability innovations are being researched and developed at the Ford Research and Innovation Center in Aachen, Germany, and around the world.

Engines today are designed to operate for many years and several hundred thousand miles in all imaginable conditions. However, in instances when an engine does fail, it is common that faulty units are simply replaced with a new engine.

Plasma Transferred Wire Arc coating technology applies a spray to the inside of the engine block that helps restore it to its original factory condition.

Traditional engine remanufacturing techniques can be prohibitively expensive, and energy intensive, requiring iron-cast parts and intricate machining processes. The Plasma Transferred Wire Arc coating technology removes the need for additional heavy parts and the processed engine block has a new life as the base of a replacement engine.

—Mark Silk, supervisor, Powertrain Products, Ford Customer Services Division Europe


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