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Thermal-Mechanical Effects of Ceramic Thermal Barrier Coatings on Diesel Engine Piston

Published online by Cambridge University Press:  17 March 2011

Jesse G. Muchai ,
Ajit D. Kelkar ,
David E. Klett  and
Jagannathan Sankar
Jesse G. Muchai
Affiliation:
NSF Center for Advanced Materials and Smart Structures Department of Mechanical Engineering North Carolina A&T State University Greensboro, NC 27411, USA
Ajit D. Kelkar
Affiliation:
NSF Center for Advanced Materials and Smart Structures Department of Mechanical Engineering North Carolina A&T State University Greensboro, NC 27411, USA
David E. Klett
Affiliation:
NSF Center for Advanced Materials and Smart Structures Department of Mechanical Engineering North Carolina A&T State University Greensboro, NC 27411, USA
Jagannathan Sankar
Affiliation:
NSF Center for Advanced Materials and Smart Structures Department of Mechanical Engineering North Carolina A&T State University Greensboro, NC 27411, USA
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Abstract

The purpose of this paper is to investigate the piston temperature and stress distribution resulting from varying coating thicknesses of Partially Stabilized Zirconia (PSZ) thermal barrier coatings for the performance in diesel engine applications. This analysis is based on the premise that coating thickness affects the heat transfer and temperature distribution in the piston. A gas dynamic engine cycle simulation code was used to obtain thermal boundary conditions on the piston then, a 2-D axisymmetric Finite Element Analysis (FEA) using ANSYS was performed to evaluate the temperature and stress distributions in the piston as a function of coating thickness. Coating thicknesses studied include 0.1, 0.2, 0.3, 0.5, 1.0, 1.5, and 2.0mm. The results indicate increased piston surface temperature with increasing coating thickness. The maximum stress on the coated piston surface was high while the substrate stress was less than the coating yield stress for all coating thicknesses. Further, the analysis showed that the interface stress at all coated conditions is low enough such that no separation of the coating is expected. The FEA results suggest an optimum coating thickness of 0.1 to 1.5 mm for diesel engine application to avoid unduly high stress in the ceramic.

Type
Research Article
Information
MRS Online Proceedings Library (OPL) , Volume 697: Symposium P – Surface Engineering 2001--Fundamentals and Applications , January 2001 , P8.10
Copyright
Copyright © Materials Research Society 2002

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