Plasma electrolytic oxidation thermal barrier coating for reduced heat losses in IC engines

Thermal barrier coatings can be used to reduce the heat losses in heavy-duty diesel engines. A relatively new coating method for thermal barrier coatings is suspension plasma-spraying. Single-cylinder engine tests have been run to evaluate how heat losses to piston, cylinder head and exhausts as well as the specific fuel consumption are influenced by coating pistons with two different suspension plasma-sprayed thermal barrier coatings and one atmospheric plasma-sprayed thermal barrier coating, and comparing the results to those from an uncoated steel piston. The two suspension plasma-sprayed thermal barrier coatings showed reduced heat losses through the piston and less heat redirected to the cylinder head compared to conventional atmospheric plasma-sprayed thermal barrier coating, while one suspension plasma-sprayed coating with yttria-stabilized zirconia as top coat material showed increased exhaust temperature. However, the indicated specific fuel consumption was higher for all tested thermal barrier coatings than for an uncoated engine. The best performing thermal barrier coating with respect to indicated specific fuel consumption was a suspension plasma-sprayed coating with gadolinium zirconate as top coat material.

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A New Design Methodology of Thermal Barrier Coating (TBC) for Internal Combustion Engines

ASME 2020 Heat Transfer Summer Conference ◽

10.1115/ht2020-9070 ◽

2020 ◽

Author(s):

Chandra Pratap Singh ◽

Arif Taibani ◽

Shankar Krishnan

Keyword(s):

Thermal Conductivity ◽

Heat Capacity ◽

Heat Loss ◽

Thermal Barrier Coating ◽

Thermal Efficiency ◽

Design Methodology ◽

Internal Combustion ◽

Thermal Barrier ◽

Barrier Coating ◽

Ic Engines

Abstract Currently available Internal combustion (IC) engines contribute 25% of the total world energy consumption. IC engines convert only 40% of the fuel energy into the indicated power[1]. Roughly, 30 percent of heat energy is lost from the combustion chamber to the environment. Interest in the design and development of thermal barrier coating (TBC) is increasing due to an increase in fuel costs and due to the decrease in high quality fuel production[2], [3]. The coating materials with low thermal conductivity and high heat capacity led to problems of high surface temperature, which degrade the volumetric efficiency and an increase in the NOx emission. On the other hand, thin TBC of low thermal conductivity and low heat capacity showed high thermal efficiency. Thin coatings could able to prevent intake air heating with effective resistance during the combustion[4]. However, fundamental relationships between thermal efficiency and thermophysical properties, structure, and durability of TBC still need to be investigated. Few studies suggested that the heat interaction study based on the crank angle position could be the best method to estimate the thermodynamics efficiency than the conventionally calculated heat rejection by the adiabatic engine[5], [6]. This work shows a design methodology to develop a thermal barrier coating (TBC), which can reduce heat loss by maintaining the minimum temperature difference between the surface and the in-cylinder gas temperature. The temperature fluctuation of TBC improves the thermal efficiency of internal combustion (IC) engines by reducing the heat loss to the coolant. This work also investigates the thermophysical behaviour of nearby available material and the applicability as a TBC.

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A Model to Predict the Influence of Inconsistencies in Thermal Barrier Coating (TBC) Thicknesses in Pistons of IC Engines

Materials Today Proceedings ◽

10.1016/j.matpr.2018.02.245 ◽

2018 ◽

Vol 5 (5) ◽

pp. 12623-12631 ◽

Cited By ~ 4

Author(s):

Parvati Ramaswamy ◽

V. Shankar ◽

V.R. Reghu ◽

Nikhil Mathew ◽

S. Manoj Kumar

Keyword(s):

Thermal Barrier Coating ◽

Thermal Barrier ◽

Barrier Coating ◽

Ic Engines

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Boron-Nitride Nanosheet Based Thermal Barrier Coating for Micro-combustor Performance Improvement

Journal of Energy Resources Technology ◽

10.1115/1.4052734 ◽

2021 ◽

pp. 1-5

Author(s):

Bao Yang ◽

Liangbing Hu ◽

Weiwei Ping ◽

Rishi Roy ◽

Ashwani K. Gupta

Keyword(s):

Thermal Conductivity ◽

Boron Nitride ◽

Thermal Barrier Coating ◽

Building Blocks ◽

Heat Losses ◽

Thermal Barrier ◽

Rocket Engines ◽

Barrier Coating ◽

Boron Nitride Nanosheet ◽

Micro Combustor

Abstract One of the major challenges in the development of micro-combustors is heat losses that results in flame quenching, and reduced combustion efficiency and performance. In this work, a novel thermal barrier coating (TBC) using hexagonal boron nitride (h-BN) nanosheets as building blocks was developed and applied to a Swiss roll micro-combustor for determining its heat losses with increased temperatures inside the combustor that contributes to improved performance. It was found that by using the h-BN TBC, the combustion temperature of the micro-combustor increased from 850K to 970K under the same thermal loading and operational conditions. This remarkable temperature increase using the BN TBC originated from its low cross-plane thermal conductivity of 0.4 W m-1 K-1to mitigate the heat loss from the micro-combustor plates. Such a low thermal conductivity in the h-BN TBC is attributed to its interfacial resistance between the nanosheets. The development of h-BN TBC provides an effective approach to improve thermal management for performance improvements of gas turbine engines, rocket engines and all various kinds of micro-combustors.

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Analysis of Effect of Thermal Barrier Coating Materials on Efficiency of IC Engines Using 3D Finite Element Method

IOSR Journal of Mechanical and Civil Engineering ◽

10.9790/1684-11485358 ◽

2014 ◽

Vol 11 (4) ◽

pp. 53-58 ◽

Cited By ~ 1

Author(s):

Durga Raghu Ram Pendyala ◽

◽

Kaarthik V.M ◽

Puviyarasan M

Keyword(s):

Finite Element Method ◽

Finite Element ◽

Thermal Barrier Coating ◽

Thermal Barrier ◽

Coating Materials ◽

3D Finite Element ◽

Barrier Coating ◽

Ic Engines ◽

3D Finite Element Method ◽

Element Method

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HOT CORROSION OF CERIA-YTTRIA STABILIZED ZIRCONIA PLASMA SPRAYED THERMAL BARRIER COATING BY EUTECTIC VANDIUM PENTAOXIDE-SODIUM SULFATE

THE IRAQI JOURNAL FOR MECHANICAL AND MATERIALS ENGINEERING ◽

10.32852/iqjfmme.vol18.iss1.83 ◽

2018 ◽

Vol 18 (1) ◽

pp. 182-192 ◽

Cited By ~ 1

Author(s):

Mohammed J Kadhim ◽

Mohammed H Hafiz ◽

Maryam A Ali Bash

Keyword(s):

Thermal Barrier Coating ◽

Hot Corrosion ◽

Monoclinic Phase ◽

Volume Fraction ◽

High Volume ◽

Thermal Barrier ◽

Air Plasma ◽

Plan View ◽

Barrier Coating ◽

Plasma Sprayed

The high temperature corrosion behavior of thermal barrier coating (TBC) systemconsisting of IN-738 LC superalloy substrate, air plasma sprayed Ni24.5Cr6Al0.4Y (wt%)bond coat and air plasma sprayed ZrO2-20 wt% ceria-3.6 wt% yttria (CYSZ) ceramic coatwere characterized. The upper surfaces of CYSZ covered with 30 mg/cm2 , mixed 45 wt%Na2SO4-55 wt% V2O5 salt were exposed at different temperatures from 800 to 1000 oC andinteraction times from 1 up to 8 h. The upper surface plan view of the coatings wereidentified for topography, roughness, chemical composition, phases and reaction productsusing scanning electron microscopy, energy dispersive spectroscopy, talysurf, and X-raydiffraction. XRD analyses of the plasma sprayed coatings after hot corrosion confirmed thephase transformation of nontransformable tetragonal (t') into monoclinic phase, presence ofYVO4 and CeVO4 products. Analysis of the hot corrosion CYSZ coating confirmed theformation of high volume fraction of YVO4, with low volume fractions of CeOV4 and CeO2.The formation of these compounds were combined with formation of monoclinic phase (m)from transformation of nontransformable tetragonal phase (t').

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