Frictional evaluation of thermally sprayed coatings applied on the cylinder liner of a heavy duty diesel engine: Pilot tribometer analysis and full scale engine test (original) (raw)
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Optimization of Thermal Barrier Coating Material for Diesel Engine Cylinder Liner
International Journal of Engineering Research & Technology, 2018
The present study focuses on improving the thermal efficiency of CI engine by decreasing the heat transfer in combustion chamber. In this paper, analyze the different ceramic powder coating materials on the Nickel chromium cast iron alloy cylinder liner by conducting various tests in order to finalize the best ceramic coating on the cylinder liner. Four different coating materials combination have been chosen for the analyses which are Yttrium Stabilized Zirconia (YSZ), Aluminum oxide (Al2O3), Aluminum Oxide and Yttrium Stabilized Zirconia (Al2O3 +YSZ), Aluminum Oxide and Titanium Oxide (Al2O3+TiO2). The optimum level of thickness 100 microns has been chosen for the observing the results. The mechanical strength test of wear test, adhesive test, SEM and EDX test, in additionally flow analyze test of CFD have been conducted. From the results, it's showed that combination of Aluminum Oxide and Titanium Oxide (Al2O3+TiO2) had better ceramic coating than other materials.
Evaluation of the friction properties of thermally sprayed coatings
Tribology and Design, 2010
In this paper, one of the tribological tests for the evaluation of friction properties is introduced. The test, named "Block-on-Ring", (in accordance with the standard ASTM G77) was carried out by the ŠKODA VÝZKUM Ltd. company and realized on renovated apparatus. The brief description of the measurement is as follows: the flat surface of the sample is pressed against the cylindrical surface of the rotating wheel. Arbitrary oil is fed to the materials' contact surface and the increasing temperature can be detected using the thermocouple that is placed in close proximity of the contact materials. Using the strain-gauge dynamometer, the friction force is recorded. The test is run on a number of periods and, including after the first expiration time, the wear track formed in the sample is measured and evaluated. The final results are the summary of partial results of the long-standing tests, which serve for the preliminary detection of the friction behaviour of the materials. The friction properties of the thermally sprayed coatings were investigated. The Cr 3 C 2-NiCr, 13% Cr and Cr 2 O 3 coatings were tested. The thin-base babbit was selected as the counterpart. The main interest was in the characterization of the friction properties in the dependence on the amount of added lubricant and on the normal load of sliding couples.
The impact of piston thermal barrier coating roughness on high-load diesel operation
International Journal of Engine Research, 2019
Thermal barrier coatings of various thickness and surface roughness were applied to the piston crown of a single-cylinder research engine and tested over a range of high-output diesel operating conditions, some near 30 bar gross indicated mean effective pressure. Three yttria-stabilized zirconia coated pistons were compared to a baseline metal piston. At each operating condition, a start-of-injection sweep was conducted to generate efficiency trends and find the optimal combustion phasing. Three variations of pistons coated with a graded-layer thermal barrier coating were tested: (1) 0.185 mm coating thickness with a surface roughness of approximately Ra = 11.8 µm, (2) 0.325 mm thickness with Ra = 11.8 µm, and (3) 0.325 mm thickness with Ra = 6.0 µm. Both coated pistons with Ra = 11.8 µm did not show any statistically significant improvement to engine performance when compared to the metal baseline piston, but did produce higher filter smoke numbers. The coated piston with Ra = 6.0 ...
Tribology and Design, 2010
The friction between a piston, piston rings and a cylinder is responsible for almost 55% of total power loss in engines. The decrease of friction in the piston area leads to a significant fuel saving and also to emission reduction. Application of a surface treatment, such as PEO, PVD, HVOF, plasma sprayed coatings, surface texturing, etc. on engine components is a way to reduce corrosion, friction, wear and weight of engines. In the paper, the potential of the application of HVOF sprayed coatings on the engine components is discussed with respect to their sliding friction properties. The technology of thermal spraying enables one to create the surface coating approximately 50 µm thick, which provides functional surface protection of the coated parts. HVOF technology offers the possibility of creating the coatings of materials based on the principle of hardmetals with high wear resistance and favourable sliding properties. Such a combination predestinates HVOF sprayed coatings for sliding applications, such as pistons of combustion engines, pumps and other hydraulic devices. In this application area they are used on a regular basis. In practice, the producers and users of thermally sprayed coatings face the problem of the interaction of the coatings and their counterparts with the presence of other media, fuels, or, in the case of sliding wear more often, lubricants. The paper describes the methodology of measurement suitable for lubricated HVOF coatings using the pin-on-disc test according to ASTM G-99 and on the evaluation of the influence of lubricants on the friction properties, wear rate and mechanism of HVOF sprayed coatings. The pin-on-disc test according to ASTM G-99 was performed on the thermally sprayed Cr 3 C 2-25%NiCr coating to determine and describe their sliding wear behaviour under different test conditions. The influence of various test parameters (load, wear track diameter, temperature, lubrication, counterpart
The effect of thermal barrier coatings on diesel engine performance
Surface and Coatings Technology, 2007
Ceramic coatings hold significant promise in the reduction of wear and abrasion failure in reciprocating and rotary engines for transportation and stationary power. They also have application as thermal barriers to improve the efficiency of the engines, by reducing energy loss and cooling requirements. In this study, the effects of ceramic coating on the performance of the diesel engine were investigated. The research engine was a fourstroke, direct injected, six cylinder, turbo-charged and inter-cooled diesel engine. This engine was tested at different speeds and loads conditions without coating. Then, the combustion chamber surfaces, cylinder head, valves and piston crown faces were coated with ceramic materials. The layers were made of CaZrO 3 and MgZrO 3 and plasma coated onto the base of the NiCrAl bond coat. The ceramic-coated research engine was tested at the same operation conditions as the standard (without coating) engine. The results indicate a reduction in fuel consumption and an improving effective efficiency of the engine.
Design and Analysis of Cylinder Liner with Different Coatings
International Journal for Research in Applied Science & Engineering Technology (IJRASET), 2022
In this project, the surface of a cylinder Liner in a diesel engine is coated with ceramic coating powders by the plasmaspray technique using Ansys and its surface behavior is subsequently analyzed. The purpose of this study is to analyze with tribological effects of surface coating for a Liner in frictional mechanism. In, with and without coated cylinder liner was analyzed with Ansys software. The modeling and analysis of the cylinder liner is carrying by the catia and ansys software. Also, the combustion flow analysis of the cylinder liner is carried by Ansys software. From the obtained test results, it was found that the coated liner having improved properties in towards the diesel engine performance. The results show less deformation and fewer scratches due to wear on the Titania-coated Liner as compared to uncoated one.
Experimental friction evaluation of cylinder liner/piston ring contact
Wear, 2011
Fuel consumption is an extremely important parameter for the automotive industry today. Anticipated emission legislative demands in combination with a rising oil price are true motivators. In engines the piston system is the largest source of frictional losses, accounting for about 50% of the total frictional losses, thus it is important to optimize. Apart from frictional losses the piston system is a large consumer of lubricating oil, a considerable contributor to the total amount of particulate emissions (PM). New materials, coatings and high-tech machining processes that previously were considered to be too expensive and therefore only used in complex applications are today becoming more affordable. It is important to develop reliable test methods to study these new concepts. The reciprocating tribometer at Volvo Technology has been updated to better evaluate the frictional difference between material combinations/surfaces; it is possible to evaluate a number of operational parameters in each experiment. The components that were studied were a piston ring running against a cylinder liner. Friction, wear and change in surface morphology were studied in the experiments. It is shown that for the introduced DoE based tribometer test the interaction of dynamic viscosity, velocity and contact pressure can be studied within one experiment. The results show differences in friction which could be explained as the surface creating beneficial contact conditions for oil film build-up. It is also apparent that surface roughness is important regardless of material properties. To better understand the correlations between friction and surface roughness a future study should include a study of similar materials with different roughness values.
An Experimental Investigation of Piston Coating on Internal Combustion Engine
The thermal efficiency of most commercially used engine ranges from 38% to 42%, as nearly 58% to 62% of energy is lost in the form of waste heat. In order to save energy the hot parts are insulated. This will lead to reduction in heat transfer through the engine, involving an increased efficiency. Change in combustion process due to insulation also affects emissions. In this study an attempt is made to reduce the intensity of thermal and structural stresses by using a layer of ceramic material. Experimental investigation is carried out under different loading conditions on single cylinder two stroke spark ignition engine with its piston crown coated with Nickel-Chromium & Al2O3 to understand the influence of thermal barrier coating (TBC) on performance characteristics. Al2O3 is chosen as a candidate material for coating the piston crown because of its desirable physical properties like low thermal conductivity, high coefficient of thermal expansion, high thermal resistance, chemical inertness, high resistance to erosion, corrosion and high strength. Thermal barrier coating (TBC) is done by using Plasma Spraying Technique. Engine working conditions are maintained constant before and after coating. Experimental results revealed that the thermal efficiency is increased by 13.75%, Mass of fuel consumption is reduced by 6.02% and brake specific fuel consumption is reduced by 9.84% between coated and bare engine.
INTERNATIONAL RESEARCH JOURNAL OF MULTIDISCIPLINARY TECHNOVATION, 2019
Improvement in thermal efficiency and reduction in emission from diesel engines are major thrust research work in all around the world. This research work is on the performance and emission characteristics of diesel engine using Low Heat Rejection (LHR) techniques of thermal barrier coated cylinder liner and piston. A piston was coated as 100 micron thickness and three cylinder liners were coated in the thickness of 100,150 and 200 micron. Piston and cylinder liners were coated with equal percentages of Alumina and Yittria Stabilized Zirconia powder using the plasma spraying coating method. The test results compared with base engine showed reduction in the performance parameter of specific fuel consumption (SFC) on an average by 6.11%, 12.78% and 16.89%, while the brake thermal efficiency increased by 1.68%,3.75% and 5.19% in 100,150 and 200 micron thickness coated cylinder liner used engine respectively. There was reduction in Carbon monoxide (CO), unburned hydrocarbon (HC) and smoke emissions levels while Nitrogen Oxide (NOx) emission was slightly higher in the coated engine compared with the uncoated engine in all load conditions. Overall, 200 microns thickness coated cylinder liner showed a better performance parameter and low emission compared with other cylinder liner coated engine.