Preliminary Testing of Metal-Based Thermal Barrier Coating in a Spark-Ignition Engine

2010 ◽  
Vol 132 (7) ◽  
Author(s):  
Michael A. Marr ◽  
James S. Wallace ◽  
Larry Pershin ◽  
Sanjeev Chandra ◽  
Javad Mostaghimi
Keyword(s):  
Heat Transfer ◽  
Thermal Barrier Coating ◽  
Substrate Surface ◽  
Temperature Fluctuations ◽  
Spark Ignition ◽  
Spark Ignition Engine ◽  
Thermal Barrier ◽  
Cylinder Wall ◽  
Test Results ◽  
Barrier Coating

A novel metal-based thermal barrier coating was tested in a spark-ignition engine. The coating was applied to the surface of aluminum plugs and exposed to in-cylinder conditions through ports in the cylinder wall. Temperatures were measured directly behind the coating and within the plug 3 and 11 mm from the surface. In-cylinder pressures were measured and analyzed to identify and quantify knock. Test results suggest the coating does not significantly reduce overall heat transfer, but it does reduce the magnitude of temperature fluctuations at the substrate surface. It was found that heat transfer can be reduced by reducing the surface roughness of the coating. The presence of the coating did not promote knock.

Preliminary Testing of Metal-Based Thermal Barrier Coating in a Spark-Ignition Engine

2009 ◽  
Author(s):  
Michael Marr ◽  
James S. Wallace ◽  
Larry Pershin ◽  
Sanjeev Chandra ◽  
Javad Mostaghimi
Keyword(s):  
Heat Transfer ◽  
Thermal Barrier Coating ◽  
Substrate Surface ◽  
Temperature Fluctuations ◽  
Spark Ignition ◽  
Spark Ignition Engine ◽  
Thermal Barrier ◽  
Cylinder Wall ◽  
Test Results ◽  
Barrier Coating

A novel metal-based thermal barrier coating was tested in a spark-ignition engine. The coating was applied to the surface of aluminum plugs and exposed to in-cylinder conditions through ports in the cylinder wall. Temperatures were measured directly behind the coating and within the plug 3 and 11 mm from the surface. In-cylinder pressures were measured and analyzed to identify and quantify knock. Test results suggest the coating does not significantly reduce overall heat transfer, but it does reduce the magnitude of temperature fluctuations at the substrate surface. It was found that heat transfer can be reduced by reducing the surface roughness of the coating. The presence of the coating did not promote knock.

scholarly journals The Influence of Thermal Barrier Coating Surface Roughness on Spark-Ignition Engine Performance and Emissions

2012 ◽  
Author(s):  
Silvio Memme ◽  
James S. Wallace
Keyword(s):  
Heat Transfer ◽  
Surface Roughness ◽  
Thermal Barrier Coating ◽  
Surface Finish ◽  
Spark Ignition ◽  
Hydrocarbon Emissions ◽  
Thermal Barrier ◽  
Piston Crown ◽  
Barrier Coating ◽  
Peak Pressures

The separate effects on heat transfer of 1) piston crown surface finish and 2) the use of a metal based thermal barrier coating (MTBC) on the piston crown of a spark ignition (SI) engine were quantified through experimental analysis in a single cylinder CFR engine. Measured engine parameters such as power, fuel consumption, emissions and cylinder pressure were used to identify the effects of the coating and its surface finish. Two piston coatings were tested: a baseline copper coating and a metal-based thermal barrier coating. Each coating was tested at multiple surface finishes. Tests showed that reducing surface roughness of both coatings increased in-cylinder temperature and pressure as a result of reduced heat transfer through the piston crown. For both coatings, this resulted in small improvements (∼3%) in power and fuel consumption, while also having a measurable effect on emissions. Oxides of nitrogen emissions increased while total hydrocarbon emissions generally decreased as a result of polishing. The polished coatings were also seen to increase in-cylinder peak pressures and burn rates. Improvements attributed to the TBC were found to be small, but statistically significant. At an equivalent surface finish, the MTBC-coated piston produced slightly higher power output and peak pressures. Hydrocarbon emissions were also seen to be significantly higher for the MTBC-coated piston due to its porosity. The effectiveness of the coating was found to be highly dependent on surface finish.

Results From the Phase II Test Using the High-Temperature Developing Unit (HTDU)

1988 ◽  
Vol 110 (2) ◽  
pp. 251-258 ◽  
Author(s):  
S. Aoki ◽  
K. Teshima ◽  
M. Arai ◽  
H. Yamao
Keyword(s):  
High Pressure ◽  
High Temperature ◽  
Thermal Barrier Coating ◽  
Phase Ii ◽  
Thermal Barrier ◽  
Test Results ◽  
High Pressure Turbine ◽  
Barrier Coating ◽  
Two Stages

Phase II of the high-temperature turbine test was performed using the High-Temperature Developing Unit (HTDU). This unit has the same two stages as the high-pressure turbine of the AGTJ-100A reheat system. The purpose of the Phase II test was to investigate the potential of candidate technologies that may be applied to the advanced engine, the AGTJ-100B. Cooling characteristics of several cooling schemes for the first stage blades, and the performance of thermal barrier coating employed on the first stage nozzles and blades, were investigated. This paper presents the Phase II test results.

scholarly journals Investigation of Cooling Performances of a Non-Film-Cooled Turbine Vane Coated with a Thermal Barrier Coating Using Conjugate Heat Transfer

Energies ◽  
2018 ◽  
Vol 11 (4) ◽  
pp. 1000 ◽  
Author(s):  
Prasert Prapamonthon ◽  
Soemsak Yooyen ◽  
Suwin Sleesongsom ◽  
Daniele Dipasquale ◽  
Huazhao Xu ◽  
...  
Keyword(s):  
Heat Transfer ◽  
Thermal Barrier Coating ◽  
Conjugate Heat Transfer ◽  
Thermal Barrier ◽  
Barrier Coating ◽  
Turbine Vane

Hot-Corrosion Behavior of Modified YSZ Thermal Barrier Coating

2014 ◽  
Vol 492 ◽  
pp. 361-364
Author(s):  
Yi Wang ◽  
Li Jia Chen ◽  
Hong Li Suo ◽  
Yi Chen Meng
Keyword(s):  
Thermal Barrier Coating ◽  
Substrate Surface ◽  
Atmospheric Plasma ◽  
Thermal Barrier ◽  
X Ray Diffraction ◽  
X Ray ◽  
Abnormal Growth ◽  
Barrier Coating ◽  
Thermal Cycling Testing ◽  
Ysz Coating

A modified YSZ thermal barrier coating (TBC) was prepared by simultaneously depositing two components, NiCrAlY and YSZ, on nicked-based superalloy DZ125 via atmospheric plasma spraying. In this study, the sodium salt was deposited on substrate surface at the deposition rate of 3 mg/cm-2. After being heated at 950 °C for 50min, the specimens were cooled to ambient temperature within 10 min. The specimens were recoated after each 10 cycles. Subsequently, the corrosion products were analyzed via X-Ray diffraction and SEM. The results indicated that deterioration of traditional YSZ coating mainly resulted from the fluxing of thermal grown oxides (TGO). Conversely, abnormal growth of TGO and enrichment of molten salt around segmentation crack were not observed in the modified YSZ thermal barrier coating. Moreover, the modified YSZ-TBC exhibited higher thermal resistance than traditional YSZ-TBC in the thermal cycling testing.

Thermal Shock Experiment and Simulation of Ceramic/Metal Gradient Thermal Barrier Coating

2007 ◽  
Vol 336-338 ◽  
pp. 1818-1822
Author(s):  
Jin Sheng Xiao ◽  
Kun Liu ◽  
Wen Hua Zhao ◽  
Wei Biao Fu
Keyword(s):  
Heat Transfer ◽  
Thermal Shock ◽  
Thermal Barrier Coating ◽  
Thermal Stresses ◽  
Initial Temperature ◽  
Thermal Barrier ◽  
Water Spray ◽  
Barrier Coating ◽  
Shock Experiment ◽  
Two Stages

A thermal shock experiment is designed to explore the thermal shock properties of ceramic/metal gradient thermal barrier coating. The specimens are heated up by oxygen-acetylene flame and cooled by water spray. The experiment procedure includes two stages, heating the specimen from the initial temperature 30°C for 40s, and then cooling for 20s. The heat transfer and the associated thermal stresses produced during the thermal shock procedure are simulated by finite element method. Experimental results indicated that the specimen of gradient coating behaves better in thermal shock experiments, which agree with the results of simulation.

Two-Dimensional Thermal Performance Analysis of a Semi-Transparent Spectral Zirconia Thermal Barrier Coating

2004 ◽  
Author(s):  
Nalini Uppu ◽  
Patrick F. Mensah ◽  
Ravinder Diwan
Keyword(s):  
Heat Transfer ◽  
Thermal Barrier Coating ◽  
Thermal Performance ◽  
Operating Temperature ◽  
Turbine Blades ◽  
The Other ◽  
Ceramic Layer ◽  
Thermal Barrier ◽  
Barrier Coating ◽  
Super Alloy

The performance of an aero engine can be increased in two ways: one by reducing the air requirement for the cooling of the turbine blades and secondly by increasing the turbine inlet temperature (TIT) that is operating temperature of the turbine blades. Taking into account the latter approach the blade material must withstand high temperatures of above 1350°C. For this enhancing purpose, protective coatings called the thermal barrier coatings (TBC) are being employed. The thermal barrier coating mainly consists of two layers; one is the metallic coating MCrAlY, which is the premiere layer over the substrate Ni based super alloy. The other is the ceramic layer made of Yttria Stabilized Zirconia (YSZ). Apart from these two layers, an intermediate layer of Al2O3 is formed by the oxidation of the aluminum in MCrAlY called the diffusion layer which also enhances the adhesion between the two layers. M stands for Nickel or Cobalt. The present study is an investigation on the in-situ thermal performance of TBCs by considering the ceramic layer as a semi-transparent media and varying its thickness and simultaneously increasing the operating temperature on its other boundary surface. The above thermal boundary value problem is modeled in 2-dimensions and solved numerically using the discrete ordinate model for radiative heat transfer in a commercial computational fluid dynamics and heat transfer software. Two samples of Ni based super alloy substrate with dimensions 40 × 100 × 3mm are considered; one sample with a thickness of 0.25 mm ceramic layer and the other sample with 1 mm coating thickness for transient thermal analysis. Simulated transient temperature histories are presented for use in a thermo-mechanical analysis in order to predict the failure modes in the TBC. The temperature distribution in TBC coating mainly depends on the radiative effects combined with heat conduction and convection and radiation at the material boundaries.

Burner Rig Testing of Thermal Barrier Coatings for Lifetime Prediction

2014 ◽  
Author(s):  
Grégoire Witz ◽  
Klaus F. Staerk ◽  
Carlo M. Maggi ◽  
Ulrich Krasselt ◽  
Hans-Peter Bossmann
Keyword(s):  
Failure Mechanism ◽  
Thermal Barrier Coating ◽  
Thermal Gradient ◽  
Field Experience ◽  
Lifetime Prediction ◽  
Cyclic Test ◽  
Thermal Barrier ◽  
Test Results ◽  
Barrier Coating ◽  
Coating Failure

Thermal barrier coating lifetime prediction has been commonly performed using furnace cyclic test results. This testing method causes coating failures driven by the bondcoat oxidation. This allows definition of lifetime prediction models representative of the field experience for thin thermal barrier coating systems where the difference between the bondcoat temperature and the coating surface are limited to 100–200 °C. Thick thermal barrier coating systems can experience coating surface temperatures 500 °C higher than the bondcoat temperature. In such cases sintering and phase transformations in the ceramic layers can also affect the coating lifetime. For this reason cyclic test methods like thermal gradient burner rig and laser heat-flux tests have been developed. They allow to test a coating system with surface temperatures >1400 °C while keeping bondcoat temperature <900 °C. The main issue of such tests is the often limited samples statistic, the reproducibility of the test conditions, and the coating failure mode that is not representative of the field experience. In Alstom, a burner rig test has been developed to solve these issues. It allows to test in parallel 10 samples, with a closed loop control system allowing live adjustment of the heat and cooling air input to keep an individually controlled constant thermal gradient with a homogeneous temperature distribution on the sample surface. Modeling of the test has been performed to understand the coating failure mechanism and to adapt the testing conditions such to get a failure mechanism closer to the relevant degradation mechanisms experienced in the field. Testing of coatings coming from the same production batch in various test campaign shows a low scatter in test results confirming that the burner rig test design allowed solving the test reproducibility and samples statistics issues. Examples will be shown how this burner rig test can be used for the development of lifetime prediction rules for thermal barrier coating systems.

scholarly journals The Importance of Thermal Barrier Coating in Compression and Spark Ignition Engines

2020 ◽  
Vol 9 (4) ◽  
pp. 1738-1742
Keyword(s):  
Thermal Barrier Coating ◽  
Internal Combustion Engines ◽  
Combustion Engine ◽  
Renewable Energy Sources ◽  
Internal Combustion ◽  
Spark Ignition ◽  
Thermal Barrier ◽  
Combustion Engines ◽  
Spark Ignition Engines ◽  
Barrier Coating

This paper explains the importance of applying thermal barrier coating (TBC) technique in internal combustion engines by providing an effective way of reducing gas emission which are carbon monoxide (CO), oxide of nitrogen (NOX), hydrocarbon (HC) including particulate matter (PM) thereby increasing engine performance (brake thermal efficiency) achieved by applying coating layers on some internal combustion engine parts using materials with low thermal conductivities and matched coefficients of thermal expansion (CTE close to the substrate material) which are mainly ceramics. Energy demand for various activities of life is increasing on a daily basis. The world depends majorly on non-renewable energy sources from fossil fuels to meet these energy demands. To be comfortable in life, better means of transportation and provision of power are required. Compression and spark ignition engines which are also called Internal Combustion Engines (ICEs) provide better transport facilities and power. However, combusting these fuels in automobile and stationary engines produces unfriendly atmosphere, contaminates water and air that are consumed by man. Pollution created as a result of combustion of gases in ICE is one of the worst man made contribution to atmospheric pollution.

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