THERMAL SCIENCE

International Scientific Journal

Thermal Science - Online First

Authors of this Paper

External Links

online first only

Study on thermal-mechanical coupling of the ceramic layer in diesel engine piston with thermal barrier coating

ABSTRACT
Piston performance has an important on vehicle reliability, efficiency and exhaust emissions. The thermal barrier coating is an effective method to prevent heat transfer from combustion chamber to the substrate. The numerical model of thermal barrier coating piston is established by using finite element method, and a comprehensive thermal-mechanical result is given to determine the influence of ceramic thickness on ceramic layer and substrate. Compared with uncoated piston, the maximum temperature and the thermal stress of substrate decreased by 3.34%, 4.09%, 5.19%, 5.95% and 6.69%, corresponding to ceramic thicknesses of 0.15mm, 0.2 mm, 0.25 mm ,0.3 mm and 0.35mm. The maximum thermal stress decreases from 78 MPa to 73 MPa. For ceramic layer of the thermal barrier coating piston, the maximum temperature appears at the top surface of the ceramic layer, while the maximum thermal stress occurs at the bottom of the ceramic layer. As the ceramics thickness increased from 0.15mm to 0.35mm, the maximum temperature of the ceramic layer increased from 322℃ to 377℃, while the maximum thermal stress decreased from 95 MPa to 89 MPa. Thermal-mechanical coupled stress analysis shows that the maximum coupling stress occurs at the pinhole and its value does not change significantly. The thickness of the ceramic layer has little effect on the pinhole, but has a great influence on the ceramic layer.
KEYWORDS
PAPER SUBMITTED: 2021-07-05
PAPER REVISED: 2022-07-01
PAPER ACCEPTED: 2022-07-12
PUBLISHED ONLINE: 2022-09-10
DOI REFERENCE: https://doi.org/10.2298/TSCI210705116L
REFERENCES
  1. Silva, F. S., Fatigue on engine pistons - A compendium of case studies, Engineering Failure Analysis, 13(2006),3, pp. 480-492
  2. Guan, Z., Y. Cui., Thermal load analysis and control of four-stroke high speed diesel engine, Thermal Science, (2020), pp. 163-163
  3. Szmytka, F., et al., Thermal fatigue analysis of automotive Diesel piston: Experimental procedure and numerical protocol, International Journal of Fatigue, 73. (2015), pp. 48-57
  4. Floweday, G., et al., Thermo-mechanical fatigue damage and failure of modern high performance diesel pistons, Engineering Failure Analysis, 18.7(2011), pp. 1664-1674
  5. Abedin, M.J., et al., An overview on comparative engine performance and emission characteristics of different techniques involved in diesel engine as dual-fuel engine operation, Renewable & Sustainable Energy Reviews, (2016), pp. 306-316
  6. Goes, Wud, et al., Thermal barrier coatings with novel architectures for diesel engine applications, Surface and Coatings Technology, 396(2020), 125950
  7. Goes, Wud, et al., Suspension Plasma-Sprayed Thermal Barrier Coatings for Light-Duty Diesel Engines, Journal of Thermal Spray Technology, 28.2(2019), pp. 1674-1687
  8. Thibblin, A., et al., Influence of microstructure on thermal cycling lifetime and thermal insulation properties of Yttria-Stabilized Zirconia thermal barrier coatings for diesel engine applications, Surface and Coatings Technology, 350(2017), pp. 1-11
  9. Caputo, S., et al., Numerical and experimental investigation of a piston thermal barrier coating for an automotive diesel engine application, Applied Thermal Engineering, 162(2019), pp. 114233
  10. Sivakumar, G., Investigation on effect of Yttria Stabilized Zirconia coated piston crown on performance and emission characteristics of a diesel engine, Alexandria Engineering Journal, 53(2014), 4, pp. 787-794
  11. Padture, N.P, Advanced structural ceramics in aerospace propulsion, Nature Materials, 15(2016), 8, pp. 804
  12. Clarke, D. R., et al., Thermal barrier coatings for more efficient gas-turbine engines, MRS Bulletin 37.10(2012),10, pp. 891-899
  13. Özel, S., et al., Optimization of the effect of thermal barrier coating (TBC) on diesel engine performance by Taguchi method, Fuel, 263(2020), 116537
  14. Gupta, M., et al., Improving the lifetime of suspension plasma sprayed thermal barrier coatings, Surface and Coatings Technology, 332(2017):550-559
  15. Che, C., et al., Uneven growth of thermally grown oxide and stress distribution in plasma-sprayed thermal barrier coatings, Surface and Coatings Technology, 203(2009), pp. 3088-3091
  16. Buyukkaya, E, Thermal analysis of functionally graded coating AlSi alloy and steel pistons, Surface and Coatings Technology, 202(2008), pp. 3856-3865
  17. Cerit, M., M. Coban ., Temperature and thermal stress analyses of a ceramic-coated aluminum alloy piston used in a diesel engine - ScienceDirect, International Journal of Thermal Sciences, 77(1)(2014), pp. 11-18
  18. Gehlot, R., Tripathi, B., Thermal analysis of holes created on ceramic coating for diesel engine piston, Case Studies in Thermal Engineering , 8(2016), pp. 291-299
  19. Garud, V., et al., Performance and combustion characteristics of thermal barrier coated (YSZ) low heat rejection diesel engine, Mater. Today: Proc, 4(2017), pp. 188-194
  20. Broatch, A., et al., Numerical simulations for evaluating the impact of advanced insulation coatings on H2 additivated gasoline lean combustion in a turbocharged spark-ignited engine, Applied Thermal Engineering , 148(2019), pp. 674-683
  21. Reghu, V.R., et al., Investigation on thermal barrier effects of 8YPSZ coatings on Al-Si alloy and validation through simulation. Materials Today: Proceedings 19(Pt 2)(2019), pp. 630-636
  22. Dhomne, S., Mahalle, A.M, Thermal barrier coating materials for SI engine, Journal of Materials Research and Technology, 8( 2019), pp. 1532-1537
  23. Wang, H., et al., Development of a thermal transport database for air plasma sprayed ZrO2-Y2O3 thermal barrier coatings, Journal of Thermal Spray Technology, 19( 2010), pp. 879-883
  24. Qi, H.Y., et al., In-situ measurement of elastic modulus for ceramic top-coat at high temperature, Journal of Central South University of Technology (English Edition), 15(2008), pp. 372-376
  25. Zhang, H., et al., Thermal analysis of diesel engine piston." Journal of Chemical & Pharmaceutical Research, 5.9(2013), pp. 388-393
  26. Adrian, I., Convective heat transfer equation for turbulent flow in tubes applied to internal combustion engines operated under motored conditions, Applied Thermal Engineering, 50.1(2013), pp. 536-545
  27. Liu, X.F., et al., Finite element analysis of thermo-mechanical conditions inside the piston of a diesel engine, Applied Thermal Engineering , 119(2017), pp. 312-318
  28. Yao, Z.M., Li, W.G., Microstructure and thermal analysis of APS nano PYSZ coated aluminum alloy piston , Journal of Alloys and Compounds 812(2020), 152162