The Ford Motor Company has developed a plasma coating technology to make old engines re-usable, while also reducing carbon emissions by up to 50%.

Called the Plasma Transferred Wire Arc, this technology applies a thermal spray inside a worn-out engine block to restore it to its original condition. This technology would potentially be applied in instances where an engine fails and needs to be re-manufatured, thus avoiding unnecessary replacement with a new engine.

“Traditional engine re-manufacturing 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,” said Mark Silk, supervisor, Powertrain Products at Ford Customer Services Division Europe.

The process of restoring worn-out engine blocks also results in less CO2 emissions, as less parts are required to give an engine new life.

“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 re-manufacture 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,” said Juergen Wesemann, manager, Vehicle Technologies and Materials at Ford Research and Advanced Engineering.