Automotive Experiences

Articles

Analysis of the Temperature Variation of Bizarre Thermal Barrier Coatings and their impacts on Engine

Thirunavukkarasu Raja , Muji Setiyo , Veeramanikandan Murugan , Sathish Dhandapani

Published
November 24, 2023

Vol. 6 No. 3 (2023)
Pages 497-514

DOI

Open Access
Share

Abstract

This article presents Ansys simulations and experimental testing to determine how TBC affects engine performance and emissions. In this work, two distinct thermal barrier coatings have been identified, and the same coating materials were subsequently sprayed onto the pistons of an internal combustion engine. Transient thermal analysis reveals that TBC-1 and TBC-2 coatings reduce surface temperature distributions by 35% and 18%, respectively, and that these engines improve Brake Thermal Efficiency (BTE) by 8.71% and 7.62%, respectively, compared to non-coated engines operating under full load. TBC-1 and TBC-2 coated engines are found to have Brake-Specific Fuel Consumption (BSFC) reductions of 27.13% and 18.81%, respectively. Complete combustion reduces emissions of CO and HC, as the heat balance sheet indicates because the conversion of energy and mechanical work are enhanced by 3.56 percentage points and 2.0 percentage points, respectively.

Keywords

CI Engine; Piston coating; Engine performance; Combustion; Pollutants

References

  1. U. Schulz et al., “Some recent trends in research and technology of advanced thermal barrier coatings,†Aerospace Science and technology, vol. 7, no. 1, pp. 73–80, 2003, doi: 10.1016/S1270-9638(02)00003-2.
  2. A. Parlak, H. Yasar, and O. Eldogan, “The effect of thermal barrier coating on a turbo-charged Diesel engine performance and exergy potential of the exhaust gas,†Energy Conversion and Management, vol. 46, no. 3, pp. 489–499, 2005, doi: 10.1016/j.enconman.2004.03.006.
  3. S. Salman, R. Köse, L. Urtekin, and F. Findik, “An investigation of different ceramic coating thermal properties,†Materials & design, vol. 27, no. 7, pp. 585–590, 2006, doi: 10.1016/j.matdes.2004.12.010.
  4. A. Skopp, N. Kelling, M. Woydt, and L.-M. Berger, “Thermally sprayed titanium suboxide coatings for piston ring/cylinder liners under mixed lubrication and dry-running conditions,†Wear, vol. 262, no. 9–10, pp. 1061–1070, 2007, doi: 10.1016/j.wear.2006.11.012.
  5. E. Buyukkaya and M. Cerit, “Thermal analysis of a ceramic coating diesel engine piston using 3-D finite element method,†Surface and coatings technology, vol. 202, no. 2, pp. 398–402, 2007, doi: 10.1016/j.surfcoat.2007.06.006.
  6. P. N. Shrirao and A. N. Pawar, “Evaluation of performance and emission characteristics of turbocharged diesel engine with mullite as thermal barrier coating,†International Journal of Engineering and Technology, vol. 3, no. 3, pp. 256–262, 2011.
  7. M. Cerit, “Thermo mechanical analysis of a partially ceramic coated piston used in an SI engine,†Surface and coatings Technology, vol. 205, no. 11, pp. 3499–3505, 2011, doi: 10.1016/j.surfcoat.2010.12.019.
  8. A. J. Modi, “Experimental study of energy balance in thermal barrier coated diesel engine,†SAE Technical Paper, 2012.
  9. N. Mittal, R. L. Athony, R. Bansal, and C. R. Kumar, “Study of performance and emission characteristics of a partially coated LHR SI engine blended with n-butanol and gasoline,†Alexandria Engineering Journal, vol. 52, no. 3, pp. 285–293, 2013, doi: 10.1016/j.aej.2013.06.005.
  10. M. A. Hoffman, B. J. Lawler, O. A. Güralp, P. M. Najt, and Z. S. Filipi, “The impact of a magnesium zirconate thermal barrier coating on homogeneous charge compression ignition operational variability and the formation of combustion chamber deposits,†International Journal of Engine Research, vol. 16, no. 8, pp. 968–981, 2015, doi: 10.1177/1468087414561274.
  11. S. Aydın, C. Sayın, Ş. Altun, and H. Aydın, “Effects of thermal barrier coating on the performance and combustion characteristics of a diesel engine fueled with biodiesel produced from waste frying cottonseed oil and ultra-low sulfur diesel,†International journal of green Energy, vol. 13, no. 11, pp. 1102–1108, 2016, doi: 10.1080/15435075.2016.1185430.
  12. A. Purwar and D. R. Mahapatra, “Design of thermal barrier coating system for scramjet using coupled thermo-structural analysis,†Transactions of the Indian Ceramic Society, vol. 75, no. 4, pp. 242–249, 2016, doi: 10.1080/0371750X.2016.1210024.
  13. T. Raja, A. Vadivel, and R. Prakash, “Investigation of Performance and Emission Characteristics of VCR Engine by Using Ceramic Coating on the Piston Crown with Using Methanol Fuel,†Applied Mechanics and Materials, vol. 854, pp. 101–108, 2017, doi: 10.4028/www.scientific.net/AMM.854.101.
  14. Y.-R. Jeng, S. Islam, K. T. Wu, A. Erdemir, and O. Eryilmaz, “Investigation of nano-mechanical and-tribological properties of hydrogenated diamond like carbon (DLC) coatings,†Journal of Mechanics, vol. 33, no. 6, pp. 769–776, 2017, doi: 10.1017/jmech.2016.106.
  15. V. Garud et al., “Performance and CombustionCharacteristics of thermal barrier coated (YSZ) low heat rejection diesel engine,†Materials Today: Proceedings, vol. 4, no. 2, pp. 188–194, 2017, doi: 10.1016/j.matpr.2017.01.012.
  16. V. K. Banka and M. R. Ramesh, “Thermal analysis of a plasma sprayed ceramic coated diesel engine piston,†Transactions of the Indian Institute of Metals, vol. 71, no. 2, pp. 319–326, 2018, doi: 10.1007/s12666-017-1184-9.
  17. M. Selvam, S. Shanmugan, and S. Palani, “Performance analysis of IC engine with ceramic-coated piston,†Environmental Science and Pollution Research International, vol. 25, no. 35, pp. 35210–35220, 2018, doi: 10.1007/s11356-018-3419-7.
  18. S. M. Abbas and A. Elayaperumal, “Experimental investigation on the effect of ceramic coating on engine performance and emission characteristics for cleaner production,†Journal of Cleaner Production, vol. 214, pp. 506–513, 2019, doi: 10.1016/j.jclepro.2018.12.040.
  19. G. Venkadesan and J. Muthusamy, “Experimental investigation of Al2O3/8YSZ and CeO2/8YSZ plasma sprayed thermal barrier coating on diesel engine,†Ceramics International, vol. 45, no. 3, pp. 3166–3176, 2019, doi: 10.1016/j.ceramint.2018.10.218.
  20. A. Vadivel and S. Periyasamy, “Experimental investigation of thermal barrier (8YSZ-MGO-TIO2) coated piston used in diesel engine,†Journal of Applied Fluid Mechanics, vol. 13, no. 4, pp. 1157–1165, 2020, doi: 10.36884/JAFM.13.04.30825.
  21. G. V. Reddy, N. G. Rasu, and T. H. Prasad, “Analysis of performance and emission characteristics of TBC coated low heat rejection engine,†International Journal of Ambient Energy, vol. 42, no. 7, pp. 808–815, 2021, doi: 10.1080/01430750.2019.1567581.
  22. V. Ayyakkannu and P. Sivanandi, “Effect of cerium oxide nanoadditive on Annona Methyl Ester in a thermally coated direct injection diesel engine,†International Journal of Ambient Energy, vol. 43, no. 1, pp. 5992–6006, 2022, doi: 10.1080/01430750.2021.1997810.
  23. E. Gingrich et al., “The impact of piston thermal barrier coating roughness on high-load diesel operation,†International Journal of Engine Research, vol. 22, no. 4, pp. 1239–1254, 2021, doi: 10.1177/1468087419893487.
  24. T. Raja, P. Sivanandi, S. Dhandabani, and V. Murugan, “Exploratory of novel thermal barrier coating on diesel engine performance,†Proceedings of the Institution of Mechanical Engineers, Part E: Journal of Process Mechanical Engineering, vol. 237, no. 5, pp. 2083–2092, 2023, doi: 10.1177/09544089231190541.
  25. Y. Gao, L. Qiao, D. Wu, Y. Zhang, and Y. Zou, “First principle calculation of the effect of Cr, Ti content on the properties of VMoNbTaWMx (M= Cr, Ti) refractory high entropy alloy,†Vacuum, vol. 179, p. 109459, 2020, doi: 10.1016/j.vacuum.2020.109459.
  26. R. Thirunavukkarasu, M. Mahendran, R. Tamilselvan, and S. Periyasamy, “Investigation on single, four and five holes fuel injector nozzle on performance and emission characteristic of diesel on a VCR engine by using ceramic coating material on the piston crown,†Materials Today: Proceedings, vol. 5, no. 2, pp. 7577–7585, 2018, doi: 10.1016/j.matpr.2017.11.430.
  27. R. Thirunavukkarasu and S. Periyasamy, “Enhancing Diesel Engine Performance and Balancing Emissions with Effect and Contribution of MgO-ZrO2 and AT13 Layered Piston,†Arabian Journal for Science and Engineering, vol. 45, no. 11, pp. 9699–9707, 2020, doi: 10.1007/s13369-020-04899-4.
Article Metrics
33
Views
17
Downloads

SCITE

DIMENSIONS

Publication Information
Published November 24, 2023
Section Articles
Copyright Copyright (c) 2023 Thirunavukkarasu Raja, Muji Setiyo, Veeramanikandan Murugan, Sathish Dhandapani
Keywords
  • CI Engine
  • Piston coating
  • Engine performance
  • Combustion
  • Pollutants

Most read articles by the same author(s)

1 2 3 > >>