UNDER THE GUIDANCE OF: Dr.I.

RAJENDRAN
(PROFESSOR & HEAD Department of MECHANICAL ENGINEEERING)

Submitted by,
I.AKILAN
M.E(CAD/CAM)
12MCC001
 This project aim is to increasing the efficiency of an internal
combustion engine.
 Ceramic coatings have applications as thermal barriers to
improve the efficiency of the engines, by reducing energy losses.
 Ceramic coatings have a significant effect in the reduction of wear
and abrasion failure in reciprocating engines.
 The main aim of this study is to evaluate the effects of
ceramic coating on diesel engines effective efficiency and
emission test at different engine loads and speeds conditions.
 Emission test and performance test’s will be conducted with 4-
stroke diesel engine with and without ceramic coating .
Jing yang, et al 2011 “advanced design and manufacturing for vehicle
body” Hunan university, china..
Thermal stress is the major factor of influencing working
condition of piston. And analyzing thermal stress and the coupling by
using FEM

HONGYUAN ZHANG, et al 2013.“surface and coatings technology”,

Shenyang ligong university, china,
Use of the finite element technique to analyze the
influence of coating materials, material phase state and the purity on
the level of the developed thermal stresses in plasma coating systems
under thermal loading conditions
 finite-element analysis method ,the coated and
uncoated piston analysis was carried.

 Then piston crown will be coated with ceramic

materials with help of APS method.

 To conduct performance & emission test on four

stroke diesel engine.Performance test will be
conducted with TBC pistons.
Study of piston crown

Problems identification

Modeling

Material Selection

Analysis

Coating methods

Performance test
 To increase performance

 To reduce emission

 To prevent corrosion

 To reduce wear

 To change the coefficient of friction

 To change material compatibility problems

Thermal Barrier Coatings
Material Like :(3Al2 O3 ;
2SiO2)+(Al2TiO2 )

Thermally Grown Oxide

Bond Material Like: (NiCrAl)

Substrate material like:

Aluminium alloy (Al2O3 )
 Mullite oxide (3Al2 O3 ; 2SiO2)
 Aluminium Titanate oxide (Al2TiO2 )
BOND COAT

 Nickel chromium alloy (NiCrAl)

BASE METAL
 Aluminium alloy (Al2O3 )
Properties/ Al alloy (3AL2 O3 ;
(Al2TiO5) NiCrAl
material 2SIO2)

Young’s modulus 90 130 20 90

(GPa)
Poisson’s ratio 0.3 0.25 0.27 0.27

Density (kg/m³) 2700 3030 4000 7870

Specific heat (J/kg K) 960 760 560 764

Thermal expansion 21 6 1 12
(1/k)x10-6
Thermal conductivity 155 5 2 16.1
(W/m K)
 Piston material Aluminum alloy

Poisson ratio 0.32

Elastic modulus of the 70GPa

piston
Material density 2700 kg /m3

Conductivity factor 160w/(m2 × K)

Coefficient of thermal 21´10-6m/ K

expansion
 Initial Conditions
 Piston top surface temperature : 4000C

 Piston skirt temperature : 110 0C

 Boundary Conditions
 The piston crown or head underside convective heat transfer
coefficient,hun1 = 672.415 W/m2k

 The piston skirt underside convective heat transfer

coefficient, hun2 = 179.31 W/m2k
EXPERIMENTAL PROCEDURE

 The engine selected for evaluation of the thermal

barrier coating is a four stroke diesel engine.

 Piston head will be coated with 0.20mm thickness

and 0.10mm thickness bond coat (NiCrAl)and
Mullite oxide + Aluminium Titanate oxide (3Al2O3 ;
2SiO2)+(Al2TiO2 ) and as coating materials.
 The emission test was conducted at different load
conditions without piston coating.

 Performance test and emission test were conducted

with different coating materials and the result are
compared.
 A comparative evaluation analysis was made between the
temperature and pressure distributions of the uncoated
aluminum alloy piston and the ceramic coated piston

 In order to reduce the stress concentration, the piston crown

should have enough stiffness to reduce the deformation and
improve the piston head performance. From the FEA
analysis representation the ceramic material, Mullite
and Aluminium titanate combation gives more

performance to the diesel engine taken for this project.

THANK
YOU