Benefits of Thermal Spray Coatings in Internal Combustion Engines, with Specific View on Friction Reduction and Thermal Management

2013 ◽  
Author(s):  
Urban Morawitz ◽  
Jan Mehring ◽  
Leander Schramm
Keyword(s):  
Thermal Management ◽  
Thermal Spray ◽  
Internal Combustion Engines ◽  
Internal Combustion ◽  
Friction Reduction ◽  
Thermal Spray Coatings ◽  
Combustion Engines ◽  
Spray Coatings

scholarly journals Enhancing the Geometrical Performance Using Initially Conical Cylinder Liner in Internal Combustion Engines—A Numerical Study

2020 ◽  
Vol 10 (11) ◽  
pp. 3705
Author(s):  
Ahmad Alshwawra ◽  
Florian Pohlmann-Tasche ◽  
Frederik Stelljes ◽  
Friedrich Dinkelacker
Keyword(s):  
Internal Combustion Engines ◽  
Thermal Stresses ◽  
Numerical Study ◽  
Cylinder Liner ◽  
Internal Combustion ◽  
Friction Reduction ◽  
Cylindrical Shape ◽  
Combustion Engines ◽  
Cold State ◽  
The Impact

Reducing friction is an important aspect to increase the efficiency of internal combustion engines (ICE). The majority of frictional losses in engines are related to both the piston skirt and piston ring–cylinder liner (PRCL) arrangement. We studied the enhancement of the conformation of the PRCL arrangement based on the assumption that a suitable conical liner in its cold state may deform into a liner with nearly straight parallel walls in the fired state due to the impact of mechanical and thermal stresses. Combining the initially conical shape with a noncircular cross section will bring the liner even closer to the perfect cylindrical shape in the fired state. Hence, a significant friction reduction can be expected. For the investigation, the numerical method was first developed to simulate the liner deformation with advanced finite element methods. This was validated with given experimental data of the deformation for a gasoline engine in its fired state. In the next step, initially conically and/or elliptically shaped liners were investigated for their deformation between the cold and fired state. It was found that, for liners being both conical and elliptical in their cold state, a significant increase of straightness, parallelism, and roundness was reached in the fired state. The combined elliptical-conical liner led to a reduced straightness error by more than 50% compared to the cylindrical liner. The parallelism error was reduced by 60% to 70% and the roundness error was reduced between 70% and 80% at different liner positions. These numerical results show interesting potential for the friction reduction in the piston-liner arrangement within internal combustion engines.

scholarly journals A review of split-cycle engines

2018 ◽  
Vol 21 (6) ◽  
pp. 897-914 ◽  
Author(s):  
Joshua Finneran ◽  
Colin P Garner ◽  
Michael Bassett ◽  
Jonathan Hall
Keyword(s):  
Thermal Management ◽  
Thermal Efficiency ◽  
Internal Combustion Engines ◽  
Combustion Engine ◽  
Internal Combustion ◽  
Combustion Engines ◽  
Engine Design ◽  
Work Assessment ◽  
In Series ◽  
Management Issues

This article reviews split-cycle internal combustion engine designs. The review includes historical work, assessment of prototypes and discussion of the most recent designs. There has been an abundance of split-cycle engine designs proposed since the first in 1872. Despite this, very few prototypes exist, and no split-cycle engines are reported to be in series production. The few split-cycle prototypes that have been developed have faced practical challenges contributing to limited performance. These challenges include air flow restrictions into the expansion cylinder, late combustion, thermal management issues, and mechanical challenges with the crossover valve actuation mechanism. The main promoted advantage of split-cycle engines is the increased thermal efficiency compared to conventional internal combustion engines. However, an efficiency improvement has not thus far been demonstrated in published test data. The thermodynamic studies reviewed suggest that split-cycle engines should be more efficient than conventional four-stroke engines. Reasons why increased thermal efficiency is not realised in practice could be due to practical compromises, or due to inherent architectural split-cycle engine design limitations. It was found that the number of split-cycle engine patents has increased significantly over recent years, suggesting an increased commercial interest in the concept since the possibility of increased efficiency becomes more desirable and might outweigh the drawbacks of practical challenges.

scholarly journals Microstructural Changes in Suspension Plasma-Sprayed TBCs Deposited on Complex Geometry Substrates

Coatings ◽  
2020 ◽  
Vol 10 (7) ◽  
pp. 699
Author(s):  
Wellington Uczak de Goes ◽  
Nicolaie Markocsan ◽  
Mohit Gupta
Keyword(s):  
Thermal Conductivity ◽  
Thermal Properties ◽  
Thermal Spray ◽  
Internal Combustion Engines ◽  
Complex Geometry ◽  
Thermal Effusivity ◽  
Internal Combustion ◽  
Spray Angle ◽  
Combustion Engines ◽  
Spray Distance

Thermal barrier coatings (TBCs) are considered a promising solution for improving the efficiency of internal combustion engines. Among the thermal spray processes, the relatively newly developed suspension plasma spray (SPS) is an attractive candidate due to its unique microstructural features that have already demonstrated increased performance in gas turbine applications. To achieve these features, thermal spray conditions play an essential role. In specific uses, such as piston of diesel engines, parameters as spray angle and spray distance pose challenges to keep them constant during the whole spray process due to the complex geometry of the piston. To understand the effect of the spray distance and spray angle, a comprehensive investigation of the produced thermal spray microstructure on the piston geometry was conducted. Flat and complex geometry surfaces were coated using the same plasma parameters while the spray angle and distance were changed. Characterization was performed using scanning electron microscopy (SEM) combined with the image analysis technique to perceive the variation of the thickness and microstructures features such as pores, cracks, column density, and column orientation. The results showed that the changes in spray angles and spray distances due to the complex shape of the substrate have a significant influence on the microstructure and thermal properties (thermal conductivity and thermal effusivity) of the coatings. The thermal conductivity and thermal effusivity were calculated by modeling for the different regions of the piston and measured by laser flash analysis combined with modeling for the flat-surfaced coupon. It was shown that the modeling approach is an effective tool to predict the thermal properties and thus to understand the influence of the parameters on the coating properties. Connecting the observations of the work on the microstructural and thermal properties, the complex geometry’s influence on the produced coatings could be diminished by tailoring the process and generating the most desirable TBC for the internal combustion engines in future applications.

scholarly journals Thermal Management Opportunity on Lubricant Oil to Reduce Fuel Consumption and Emissions of a Light-Duty Diesel Engine

2021 ◽  
Vol 312 ◽  
pp. 07023
Author(s):  
Davide Di Battista ◽  
Fabio Fatigati ◽  
Marco Di Bartolomeo ◽  
Diego Vittorini ◽  
Roberto Cipollone
Keyword(s):  
Diesel Engine ◽  
Fuel Consumption ◽  
Thermal Management ◽  
Internal Combustion Engines ◽  
Thermal Stabilization ◽  
Internal Combustion ◽  
Combustion Engines ◽  
Warm Up ◽  
Lubricant Oil ◽  
Light Duty

The high viscosity of the lubricant oil in internal combustion engines at cold starts is responsible for poor friction reduction and inadequate thermal stabilization of metallic masses and represents a major bottleneck in the efforts to reduce specific fuel consumption and pollutant emissions. Consequently, the possibility of integrating techniques for proper thermal management of the lubricant oil on internal combustion engines is of utmost importance to both homologation and daily on-road operation. Main options for reducing the warm-up time for the engine lubricant are the upgrade of the engine cooling and lubricating circuits, dedicated heating, different flow management of the oil/coolant heat exchanger, a renewed design of the oil sump or a thermal storage section to increase the oil temperature in the early phases of the warm up. The paper presents a new opportunity, using a hot storage medium to heat up the oil in the early phase of a driving cycle. A certain quantity of hot water, so, is stored in a tank, which can be used to warm up the lubricating oil when the engine is started up. The heating of this service water can be done by using exhaust gas heat, which is always wasted in the atmosphere. The activity is realized on an IVECO 3.0 L light-duty diesel engine, during a transient cycle (NEDC) on a dynamometric test bench. The benefits in terms of both fuel consumption and CO2 emissions reduction. The characterization of the backpressure associated with an eventual additional heat exchangers and the more complex layout of the oil circuit is assessed, as well as the transient effects produced by the faster oil warm-up and oil-coolant interaction on the engine thermal stabilization.

scholarly journals A Review of Dynamic-Tribological Simulation Methods for Sliding Bearings in Internal Combustion Engines

2021 ◽  
Vol 2101 (1) ◽  
pp. 012014
Author(s):  
Dehui Tong ◽  
Ziyu Diao ◽  
Nannan Sun ◽  
Xiangning Du ◽  
Yanyan Zhang ◽  
...  
Keyword(s):  
Internal Combustion Engines ◽  
Simulation Models ◽  
Internal Combustion ◽  
Friction Reduction ◽  
Material Structure ◽  
Combustion Engines ◽  
Calculation Methods ◽  
Sliding Bearings ◽  
Existing Problems ◽  
Wear Calculation

Abstract The problem of friction reduction and wear resistance of sliding bearings is one of the key factors in determining the overall performance of internal combustion engines. This paper investigated and summarized the theoretical and simulation models of multi-body dynamics of crankshaft system, tribology of sliding bearings, and the wear calculation methods of the shaft-bearing friction pairs. Existing studies show that the dynamics model, hybrid lubrication model, and the friction and wear models request to be upgraded by comprehensively considering the material, structure, manufacturing process, working conditions, and etc. Based on the research status and existing problems of the above analyses, this paper summarizes the simulation models applicable to the field of dynamics and tribology of sliding bearings and presents the prospects for optimization of wear calculation methods for sliding bearings.

Piston dynamics, lubrication and tribological performance evaluation: A review

2018 ◽  
Vol 21 (5) ◽  
pp. 725-741 ◽  
Author(s):  
Cristiana Delprete ◽  
Abbas Razavykia
Keyword(s):  
Power Loss ◽  
Internal Combustion Engines ◽  
Internal Combustion ◽  
Tribological Performance ◽  
Operating Conditions ◽  
Friction Reduction ◽  
Design Parameters ◽  
Combustion Engines ◽  
Piston Skirt ◽  
Secondary Motion

Mechanical power loss of lubricated and bearing surfaces serves as an attractive domain for study and research in the field of internal combustion engines. Friction reduction at lubricated and bearing surface is one of the most cost-effective ways to reduce gas emission and improve internal combustion engines’ efficiency. This thus motivates automotive industries and researchers to investigate tribological performance of internal combustion engines. Piston secondary motion has prime importance in internal combustion engines and occurs due to unbalanced forces and moments in a plane normal to the wrist pin axis. Consequently, piston executes small translations and rotations within the defined clearance during the piston reciprocating motion. Mechanical friction power loss and lubrication at piston skirt/liner and radiated engine noise are dramatically affected by piston secondary dynamics. The lubrication mechanism, piston secondary motion and tribological performance are affected by piston design parameters (piston/liner clearance, wrist pin offset, skirt profile, etc.), lubricant rheology, oil transport mechanism and operating conditions. Therefore, this review is devoted to summarize the synthesis of main technical aspects, research efforts, conclusions and challenges that must be highlighted regarding piston skirt/liner lubrication and piston dynamics and slap.

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