Low Heat Rejection Engine
Low Heat Rejection Engine
SAE TECHNICAL
PAPER SERIES 2000-01-2918
B. B. Ghosh
IIT Kharagpur
400 Commonwealth Drive, Warrendale, PA 15096-0001 U.S.A. Tel: (724) 776-4841 Fax: (724) 776-5760
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ISSN 0148-7191
Copyright © 2000 Society of Automotive Engineers, Inc.
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2000-01-2918
B. B. Ghosh
IIT Kharagpur
Table - 1
So, in the present research, efforts have been made in required proportions (percentage by Weight) after mixing
the development of low cost ceramic coating process thoroughly and followed by melting the resulting mixture
0 0
with a new bond coat for IC engine applications. in an oil fired furnace at about 1300 -1350 C, quenching
the melted mass in water to obtain the small flakes of
PRESENT WORK glass particles called "frit." The fritted glass in
combination with clay (5 percent), water (40 percent) and
Though the plasma spray is a widely used ceramic other conventional mill additions which may be selected
coating process, but it requires a lot of consideration from NaNO3, BaCl2, MgSO4, and the like in a quantity
before processing. Coating characteristics like coating less than 0.05 percent of the amount of the frit used,
thickness, porosity, size distribution and shape of pores, milled in a porcelain lined ball mill with porcelain ball and
the presence and distribution of different phases and the finally sieved through -300 mesh (B.S.Sieve) [12].
adhesion of the coating to the substrate are particularly
important. Moreover, the coating of aluminium piston with Preparation of Cover Coat (Y-PSZ) : The raw
ZrO2 is very difficult and normally ends in failure due to materials used for making Y-PSZ were commercial
the large difference in coefficient of thermal expansion. grade zirconia (ZrO2, 98%) and GR (Guaranted Reagent)
The other difficulty with plasma spray is the inability to grade yttria (99.9%). The mixture of zirconia and yttria in
coat a thick layer in order to establish a large thermal varying ratios was mixed thoroughly in dry condition in a
barrier coating. So, it is essential to identify a ceramic porcelain lined ball mill for about 4 hours and finally
coating technique which offers a cost effective engine sieved through - 300 mesh BS sieve. The mixed batches
performance improvements. (in wt%) were then calcined at different temperatures
o o
and time varying between 1000 and 1400 C for 1 hour
Development of Coating (Vitreous to 8 hours.
Enamelling Technique) [11] :
Preparation of Thermal Barrier Coating (TBC) :
In modern technology there are many instances where
the required bulk and surface properties do not occur in The frit obtained from the base glass composition was
one material. To overcome this problem, surface ground in a ball mill with required mill additions in wet
coatings are used and when the substrate material is condition to obtain a slip. The slip was first applied on a
metal and coating the glass, the system is referred to as pre-cleaned metal surface by spraying and after drying,
"vitreous enamel." The coating of metal with a thin layer the coated work piece was fired in an electric furnace at
o
of glass can be achieved only at the temperature at about 950 -1020 C for about 5 - 15 minutes depending
which the glass softens and fuses usually between 750
0 on the size of the work piece by using technique
0
and 850 C. It is this firing process which gives vitreous commonly followed for vitreous enamelling. This coating
enamel its mirror-like surface and makes it resistant to is termed as bond coat and serves for good bonding of
0
service temperatures up to 1000 C. This enamelling the TBC with metal substrate.
technique is broadly divided into two parts. The slips for the TBC were prepared in the same way as
that of the bond coat but in addition to mill additions, it
(a) Preparation of metal surfaces and was ground with increasing amounts of Y-PSZ till smooth
(b) Making of frits (glass) and its application. and glossy surface of the coating is achieved.
Table - 2
Properties of thermal barrier coatings
Properties Results
1. Thermal barrier
0 0
(a) At 800 C +/- 10 C
(10 minutes standing at test temperature
and 10 minutes at room temperature) 100 cycles (no damage)
0 0
(b) At 1000 C +/- 10 C
(10 minutes standing at test temperature
and 10 minutes at room temperature) 30 cycles (no damage)
procedure was followed by using the technique occur here since glass-ceramic coating is supposed to
commonly applicable for vitreous enamelling. Some test be non-porous or having very few and minute pores
results of thermal barrier coatings are presented in Table caused due to some other factors.
- 2. Poor adherence causing flaking or chipping has been a
problem with some plasma sprayed coatings. The
Differences of this Process Over Plasma adhesion of plasma sprayed ceramic coatings to metals
Process : is generally poor but can be considerably improved if a
bond coat or inter layer of glass is used. Generally, the
The glass - ceramic coating can be used for coating
plasma sprayed layer are very thin i.e 100-250 microns
metal surfaces by conventional vitreous enamelling
are used. But a thick layer of 800-1000 microns or even
technique (as described earlier) which is simple and
more is possible if the coating is done by vitreous
cost-effective as compared to the plasma sprayed
enamelling technique.
process requiring high instrument or equipment and
coating materials.
The raw materials and equipments required for vitreous Major Limitations :
enamelling technique, is entirely indigenous whereas, the The maturing temperature of thermal barrier coating is
0
plasma gun and coating materials are mostly imported. around 1000 C and due to which all kinds of metallic
Almost invariably, the plasma sprayed partially stabilized substrate are not suitable for coating purposes; only
zirconia coatings used for thermal barrier purposes have stainless steel and super alloys viz. nimonic and inconel
substantial porosity, providing easy passage to oxygen are used.
and other corrosive fluids and this makes the substrate
susceptible to oxidation / corrosion. This oxidation /
corrosion phenomena due to porosity generally does not
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At higher compression ratio, the temperature and configurations, different test conditions and different
pressure of air at the beginning of injection are higher. In process of analysis.
insulated engine this pressure and temperature are After 300 hours run of the engine with ceramic coated
definitely higher than the base line engine. On the other piston, ceramic material was worn out negligibly along a
hand, at lower compression ratio, the temperature and circular ring on the top of the piston cap (stainless steel
pressure of air at the begining of injection are lower, in plate), which seems that the coating has sufficient
base metal engine relative to ceramic coating. So, in durability to complete the experiments with ceramic
both of the cases the difference become higher. If the coating on the top of piston. In the second run no such
injection is timed a few degrees of crank rotation before loss of ceramic coating was observed.
TDC, premixed combustion is shifted to diffusion The indigenous technology by which the piston head was
combustion [16, 1]. The fuel is introduced into the ceramic coated is found effective. The technology is
cylinder near peak temperature conditions. Ignition much more economical and simpler than the plasma-
occurs before a large amount of fuel mixes to spray process usually used for coating with ceramics.
stoichiometric values. The rate of pressure rise and
maximum pressure are reduced. Though the engine ACKNOWLEDGMENTS
operation is smooth but the power developed by the
engine is reduced due to burning of major part of fuel The research work leading to this paper was carried out
during expansion stroke i.e. after burning phase. With an under the sponsorship of the All India Council for
advance injection timing pressures and temperatures in Technical Education. The authors thankfully
the cylinder are too low. These conditions are not acknowledge the support.
sufficient to auto ignite the mixture (charge). A greater
amount of fuel is accumulated in the combustion REFERENCES
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Project Supervised