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Low Heat Rejection Engine

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67 views11 pages

Low Heat Rejection Engine

paper about Low heat rejection engine, the ceramic coating material is used in the different parts of combustion chamber.
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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SAE TECHNICAL
PAPER SERIES 2000-01-2918

Glass Ceramic Coating-an Alternative to


Plasma Spray for Internal Combustion
Engine Components
P. K. Bose, R. A. Beg and S. K. Saha
Jadavpur Univ.

B. B. Ghosh
IIT Kharagpur

S. K. Das and Amitava Majumdar


Central Glass and Ceramic Research Institute

International Fall Fuels and Lubricants


Meeting and Exposition
Baltimore, Maryland
October 16-19, 2000

400 Commonwealth Drive, Warrendale, PA 15096-0001 U.S.A. Tel: (724) 776-4841 Fax: (724) 776-5760
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Copyright © 2000 Society of Automotive Engineers, Inc.

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2000-01-2918

Glass Ceramic Coating-an Alternative to Plasma Spray for


Internal Combustion Engine Components
P. K. Bose, R. A. Beg and S. K. Saha
Jadavpur University

B. B. Ghosh
IIT Kharagpur

S. K. Das and Amitava Majumdar


Central Glass and Ceramic Research Institute
Copyright © 2000 Society of Automotive Engineers, Inc.

ABSTRACT heavy fuel. Zirconia has a coefficient of expansion nearly


equal to that of steel combined with a low thermal
A simple and cost effective vitreous enamelling conductivity, particularly in sprayed form. It is thus
technique is being adopted in the application of thermal particularly well suited to provide combustion chamber
barrier coating for internal combustion (IC) engine insulation and hence reducing energy loss to coolant.
components. The raw materials including the process of Coating may also be applied to the piston top to resist
coating are less costly in comparison to plasma spray the erosive damage caused by detonation [3].
technique. The coating using yttria partially stabilized Coating can be done by using plasma gun or flame
zirconia with this technique is found effective for spray. With improved bond coats such as nickel
insulation of the engine components. The results aluminate and compatible fiber materials such as
obtained from this process are comparable with the brunshond pad ceramic coatings have become durable
published results using plasma spray [1]*. At the speed [4]. Zirconia with yttria additive i.e. ZrO2 - 0.08 Y2O3 as a
of 1500 rpm, brake specific fuel consumption (BSFC) thermal barrier coating and Ni-16.8, Cr-6.0, Al-11.8,Y2O3
decreases upto 9.99% with 200 micron (µ) glass ceramic bond coatings offer an attractive thermal barrier coating
coating piston whereas with 500 µ coating, it decreases system for an adiabatic diesel engine [5-6].
0
upto 19.67% with advanced injection angle (40 before As a structural material, glass has an excellent
top dead centre) resulting higher thermal efficiency insulating qualities, low expansion ratios and low cost.
compared to base line engine. But the material is not having sufficient strength to
withstand the different stresses as an engine
INTRODUCTION components [7]. Early, ceramics (glass) have been used
in spark plug as an electrical insulator. During the 1950's
Thermal barrier coatings, consisting of a ceramic layer interest grows to the ceramic engineers in using ceramic
applied over a bond-coat layer have been developed for coatings on engine components to resist thermal
diesel engine components especially for combustion loadings [8]. During 1970's compounds of silicon-carbide
chamber to improve efficiency and increase the life of the (SiC) and silicon-nitride (Si3N4) were used in cylinder
metal parts. In order to increase component lifetime, it is construction [7,9,10].
necessary to increase not only material bulk properties, The most popular ceramic coating for internal
but especially the surface properties. It is often not combustion (IC) engine components is the plasma
possible economically to improve simultaneously both sprayed zirconia (PSZ) into a metal substrate with
bulk and surface properties by alloying, as is the case for suitable bond coat which can be done by using plasma
stainless steels. The most economical way to ensure gun or flame spray [6]. Though plasma spray technology
increased life time and operational safety of diesel has considerable potential in diverse areas of
engine components is to use a coating in order to application but the process of coating and the spray
improve surface properties [2]. equipments are very costly. Available informations reveal
Ceramic coatings applied to the piston top have been the fact that appreciable attention has not yet been paid
used to provide thermal insulation, decreasing heat in developing low cost alternative coating technique with
losses due to the high and cyclic temperatures, as well suitable bond coat.
as protection against corrosion due to acid attack from
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Table - 1

Composition Range vs. Constituents


Constituents SiO2 Al2O3 B2O3 Na2O K2O BaO CaO MoO3 V2O3 MnO2 F2
Composition 45.0- 5.0- 15.0- 5.0- 3.0- 4.0- 5.0- 0.1- 0.5- 1.0- 3.0-
Range(wt%) 47.0 7.0 17.0 7.0 5.0 6.0 7.0 0.2 1.5 2.5 5.0

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.

It has been presented in the flow sheet (A) and (B).


Process of Coating :
Preparation of Bond Coat (Glassy Phase) : The slips for the TBC coatings thus obtained were then
applied on the fired bond coated metal surface by
A number of high temperature resistant alumino - boro
spraying and fired after each application to achieve
silicate base glass compositions (in wt%) have been
desired thickness so as to control thermal stress and to
formulated is shown in Table - 1.
avoid coating failure. Here, the TBC coatings containing
The raw materials used were of commercial grade for
increased amounts of Y-PSZ were used as it gradually
silica flour, feldspar, deca-borax, fluorspar and L. R.
goes on top surface where the ratio of the base glass
(Laboratory Reagent) grade for barium carbonate,
and Y-PSZ was 1:1 by weight. The entire application
ammonium molybdate, vanadium pentaoxide and
manganese dioxide. The powdered ingredients in the
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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)

2. Gradient obtained without


0 0 0
cooling system at 1000 C 175 - 180 C

3. Gradient obtained with dry


0 0 0
cooling system at 1000 C 650 - 675 C

4. Thermal shock resistance (from red 100 cycles without


0
hot condition at 1000 C to room temperature) any damage

5. Coat thickness 800 - 1000 microns

6. Abrasion resistance(in P.E.I. 1.10 - 1.27


abrasion tester); Loss in weight
-2
values in mg. cm against 50,000 cycles.

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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Modification of the Piston : RESULTS AND DISCUSSION :


In the new coating technique both bond coat and PSZ
0
was matured at about 900 C, so it was difficult to mature Fuel Consumption and Brake Thermal
the coating on aluminium piston directly and to withstand Efficiency
that temperature for aluminium alloy also. Thus, the
The variation of brake specific fuel consumption and
piston was modified and a circular plate of stainless steel
brake thermal efficiency with respect to fuel-air ratio at
- 310 material was used on the head of the piston as a
different injection timings and different compression
piston cap. The cap was coated with this technique and
ratios are shown in figures (2-5 and 6-9). Results show
fixed on the piston with the help of pins around the
that specific fuel consumption is increased consequently
piston body. The original piston, the modified shape of
decreasing brake thermal efficiency with ceramic coated
the piston, the shape of the circular piston head cap and
piston operation compared to base line metal operation.
the final shape of the piston with ceramic coated cap are
The increase in fuel consumption in a ceramic coated
shown in figures 1(a, b, c, d) and the specifications of the
engine is basically due to deterioration of fuel
stainless steel are tabulated in Table - 3.
combustion. The deterioration of fuel combustion mainly
is caused by the effect of ignition delay. The combustion
Table - 3 chamber wall temperature of an insulated piston engine
Specification for SS-310 is higher than that of a without insulated piston engine.
Charged air in the cylinder absorbs heat emanating from
Cmax = 0.25 Pmax = 0.045 the high temperature chamber wall. Therefore, the
charged air expands, thus lessening the amount of
Simax = 1.50 Ni = 19.00 / 22.00 intake air. The end result is poor fuel-air mixing. Alkidas
[13,14] also suggested same reason for the
Mnmax = 2.00 Smax = 0.030 deterioration in combustion of a IDI diesel engine with an
air-gap insulated piston. The characteristics feature of
Crmax = 24.00 / 26.00 the combustion process of the ceramic coated engine is
the decrease in the portion of premixed combustion due
To achieve a meaningful insulation results which can to the effect of ignition delay with the increase of wall
reflect an improvement in engine efficiency, a 5 mm temperature and an increase in proportion of diffusion
coating is needed [5]. But plasma spray coating combustion and late burning i.e. longer in combustion
technology is in the 0.25 to 0.5 mm thickness range, duration. With heat release shifted later in the cycle, less
because beyond these values, spalling occurs due to useful work is extracted from the ceramic coated engine.
thermal stress. Moreover, a lot of problems are The decrease in volumetric efficiency and the effect of
associated with using thick insulation on the engine ignition delay are the main reasons for the deterioration
components. First, mechanical reliability of the coating is of fuel combustion resulting increase in fuel consumption
poor for thickness beyond 0.5 mm. Second, the and subsequent reduction in brake thermal efficiency. In
combustion chamber with high surface temperature due this connection, Lyn [15] showed that the engine cycle
to thick insulation causes a dramatic deterioration in efficiency is maximized when the centroid of the heat
volumetric efficiency [12]. To mitigate these difficulties release diagram coincides with top dead centre.
and to achieve meaningful insulation effect, 200 µ (0.2 Prolonged combustion of the ceramic coated engine
mm) and 500 µ (0.5 mm) thick coatings were used on the cause the heat release diagram centroid to shift away
piston head cap for this experimental investigations. from top dead centre resulting in decrease of engine
efficiency for the ceramic coated engine compared to
EXPERIMENTATION : base line metal engine.
At 30% of the rated load, the increase in BSFC during
coating tests with respect to base line are listed below in
Tests were conducted on a CI version of a Ricardo
Table - 4.
variable compression engine with diesel fuel at different
part loads, rpms, injection timings and compression TABLE - 4
0
ratios. Injection timings were varied from 30 before top Increse in BSFC vs. Injection Timings at
0
dead centre (BTDC) to 45 BTDC, compression ratios Compression Ratios 17, 18, 19 and 20
were varied from 17:1 to 20:1 and engine speed were
varied from 1125 to 1500 rpm. Before CR - 17 CR - 18 CR - 19 CR - 20
Tests were also carried out on the same engine by using TDC (%) (%) (%) (%)
0
vegetable oil such as esterified linseed oil and blends of 30 31 40.93 0.82 20.4
linseed oil with diesel oil at different ratios. All the tests injection timing
0
35 20 17.39 -4.92 11.42
were conducted at identical running conditions. During injection timing
the tests, coating thickness were varied such as 0.2 mm 40
0
2.21
and 0.5 mm respectively. injection 10.91 -9.99 0
timing
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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
chamber during the premixed phase before the ignition.
As a result, at high rate premixed heat release is 1. Assanis, D., Wiese, K., Schwarz E., and Bryzik, W.,
obtained. Assanis and et al. [1] suggest from their "The Effects of Ceramic Coatings on Diesel Engine
experimental results that by advancing the injection Performance and Exhaust Emissions," SAE paper-
timing, the shift in combustion caused by the ceramic 910460, 1991.
coating on the piston is partially counter acted. The 2. Kvernes, I., and Hoel, R.H., “Advanced Coating
ceramic piston achieves the same premixed heat release Developments for Internal Combustion Engine
rate even more than base line. For these reasons, the Parts,” SAE Paper-870160, 1987.
performance of the ceramic coated engine (% of 3. Parker, D.A., “Ceramics Technology Application to
increase of BSFC with respect to base line) is better at Engine Components,” Twenty-First John Player
higher injection advance (40o) angle. At 40o injection Lecture, Proc. Instn. of Mech, Engrs. vol.199 no. A3,
timing (beforeTDC)% of increase of BSFC with respect 1985 pp. !35-150.
to base line is minimum for different CR and improves in 4. Tolokan, R.P., Nablo , J.C., and Brady, J. B.,
“Ceramic to Metal Attachment Using Low Modulus
CR-19 (about 10%).
BRUNSBOND Pad,” Transaction of the ASME, vol-
104, July, 1982.
CONCLUSION
5. Glance, P., “Designing with Ceramics,” Ceramic
Engineering Science Proceeding, 5, 1984.
Relatively few results have been published on heat
6. Kamo, R. and Bryzik, W., “Cummins TACOM
insulation of indirect injection (IDI) diesel engines using
Advanced Adiabatic Engines,”. SAE Paper-840428,
ceramic coating on the top of the piston. It is worth noting
1984.
that most of them used plasma spray PSZ for insulation.
7. Churchill, R.A., Smith , J.E., Clark , N.N., and Turton,
Moreover, available informations reveal the fact that
R.A., “Low Heat Rejection Engines--A Concept
appreciable attention has not yet been paid in developing
Review,” SAE Paper-880014, 1988.
low cost alternative process of PSZ coating with suitable
8. French, C.C.J., “Ceramics in Reciprocating Internal
bonding coat instead of from molybdenum and nickel
Combustion Engines,” SAE Paper-841135, 1984.
aluminide. So far, these view points, the present
9. Pasto, A.S., “Silicon Nitride - Cordierite Composites
investigation was carried out in a IDI swirl type Ricardo
for Diesel Engine Applications,” Ceramic Engineering
variable compression engine using low cost ceramic
Science Proceeding, 5, 1984.
coating costing Rs. 50-55/- per Sq.m. in comparison to
10. Worthen , R.P., Pasto, A.E., “Ceramic Engine
plasma spray coating costing around Rs. 1000/- per
Components,” SAE Paper-881150 1989.
Sq.m.
11. Beg, R.A., Bose, P.K., Ghosh, B.B., Banerjee, T.K.,
Although some interesting results have been obtained,
and Ghosh, A.K., “Experimental Investigations On
the experimental results with this alternative technology
Some Performance Parameters of a Diesel Engine
of coating and bonding materials are very much inclined
Using Ceramic Coating on the Top of the Piston,”
to the published results with plasma sprayed PSZ . The
SAE Paper-970207, 1997.
obtained results are due to the thickness of the coating,
different process of application, different engine
Downloaded from SAE International by Tsinghua University, Friday, October 06, 2017

12. Majumdar, A,. Das, S.K., Dutta, S and Biswas, K.K., Jadavpur University, Calcutta, India
"Glass Ceramic Coating for Steel and Nimonic Alloy,"
Trans. Ind., Ceram. Soc., 45 (2) 43-45, (1986). 3. Ph.D. (Thermal Engg.) in the year 1993.
13. Assanis, D.N., and Mathur, T., “The Effect of Thin Indian Institute of Technology (Powai )
Ceramic Coatings on Spark Ignition Engine Bombay, Mumbai, India
Performance,” SAE Paper - 900903, 1990.
14. Alkidas, A.C., "Effects of Injector Tip Configuration Publication
on the Performance and Emissions of an Uncooled
Diesel," SAE paper - 881613, 1988. International Journal - 17 nos.
15. Alkidas, A.C., "The Influence of Partial Suppression National Journal - 2 nos.
of Heat Rejection on the Performance and Emissions International Cnference
of a Divided Chamber Diesel Engine," SAE paper- /Symposium - 18 nos.
860309, 1986. National Conference
16. Lyn, W.T., "Calculations of the Effect of Rate of Heat /Symposium - 19 nos.
Release on the Shape of Cylinder Pressure
Diagrams and Cycle Efficiency," Proc. Inst. Mech. Thesis Supervised
Engineers (A.D.) No. 1., 1960-61.
17. Dickey, D.W., "The Effect of Insulated Combustion M.M.E. Thesis guidence - 11 nos.
Chamber Surfaces on Direct Injected Diesel Engine Ph.D. Thesis Guidence - 5 completed
Performance, Emissions and Combustion," SAE 7 ongoing
paper - 890292, 1989.
Project Supervised

CONTACT Supervised 8 nos. sponsored project under different


funding agencies, Govt. of India.
Name : Dr. P.K. Bose
Designation : Professor, Mechanical Engg. Dept. Completed - 6nos.
On going - 2 nos.

Address : Mechanical Engg. Dept. Total Amount - 63,20,000/-


Jadavpur University
Calcutta - 700 032, India Patent Obtained

Contact No. 2 provisional patent obtained


Telephone 91-33-4724927 (Office) 1 provisional patent applied
91-33-463 5158 (Residence)
Book Published
Fax 91-33-4724927 (Office)
Email [email protected] Published
[email protected] 1. Car and Driving
[email protected] [Papas Publication)]

Educational background On progress


2. (a) Applied Mechanics-Problems and Solution
Educational Qualification [Narosa Publishing House]
(b) Design and Manufacturing
1. B.E. (Mechanical) in the year 1975. [Everest Publishing House]
Regional Engg. College, Durgapur
University of Burdwan, West Bengal
India

2. M.M.E. (Heat Power Engineering) in the year 1978.


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