IMPROVING THERMAL EFFICIENCY OF DIESEL ENGINE BY USING … · 2017-07-26 · A dopant stabilized cubic structured zirconia, cubic zirconia, is synthesized in various colors for use

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International Journal of Mechanical Engineering and Technology (IJMET) Volume 8, Issue 7, July 2017, pp. 834–845, Article ID: IJMET_08_07_092

Available online at http://www.iaeme.com/IJMET/issues.asp?JType=IJMET&VType=8&IType=7

ISSN Print: 0976-6340 and ISSN Online: 0976-6359

© IAEME Publication Scopus Indexed

IMPROVING THERMAL EFFICIENCY OF

DIESEL ENGINE BY USING CERAMIC

COATING ON CYLINDER LINER AND PISTON

HEAD

M. Soundar

Assistant Professor, Mechanical Engineering,

SRM University Ramapuram campus, Chennai, India

P. Anand

Associate Professor, Mechanical Engineering,

Veltech Dr RR & Dr SR University, Avadi, Chennai, India

V. Ramesh

Assistant Professor, Mechanical Engineering,

Veltech Dr RR & Dr SR University, Avadi, Chennai, India

ABSTRACT

In general only 40% of power produced in the engine is converted into useful work

other than that 30% of heat escape through exhaust and 30% of heat is which cannot

be converted into useful work is removed as waste heat with the help of cooling system.

To convert this waste heat into useful work the cylinder liners and piston head is coated

with ceramic coating. This will lead to reduction in heat transfer through the engine,

involving an increased efficiency. Change in combustion process due to insulation also

affects emissions. Higher gas temperature should reduce the concentration of

incomplete combustion products at the expense of an increase in nitrogen oxides (NOx).

However a decrease in carbon monoxide (CO) unburned hydrocarbons (HC) is

observed. Here we are going to analyze the uncoated cylinder with coated one using

ANSYS and in experimental method using thermal image camera. The result depicted

that the ceramic coated cylinder is more efficient than uncoated one.

Key words: Zirconium Oxide, Thermal Imaging Camera, Cylinder Liner, Piston Head.

Cite this Article: M. Soundar, P. Anand and V. Ramesh, Improving Thermal Efficiency

of Diesel Engine by Using Ceramic Coating On Cylinder Liner and Piston Head,

International Journal of Mechanical Engineering and Technology, 8(7), 2017, pp. 834–

845.

http://www.iaeme.com/IJMET/issues.asp?JType=IJMET&VType=8&IType=7

Improving Thermal Efficiency of Diesel Engine by Using Ceramic Coating On Cylinder Liner and

Piston Head


INTRODUCTION

In automobile sector, the main objective is to improve the performance by reducing the fuel

consumption of an engine and increase the power. The diesel engine has the highest thermal

efficiency of any standard combustion engine due to its very high compression ratio. Diesel

engines are more efficient than gasoline (petrol) engines of the same power rating resulting in

lower fuel consumption. The increased fuel economy of diesel engine over the petrol engine

produces less carbon dioxide per unit distance. A design and development of a high power with

low heat rejection, direct injection automotive diesel engines requires a thorough knowledge of

in cylinder combustion and heat transfer characteristic. These information and analysis will be

helpful in designing an energy efficient engine, by coating with ceramics over the cylinder liner

and piston head. Thermal barrier coatings are highly advanced material systems applied to

metallic surfaces, such as gas turbine aero-engine and diesel engine parts, operating at elevated

temperatures. These coatings serve to insulate metallic components from large and prolonged

heat loads by utilizing thermally insulating materials which can sustain an appreciable

temperature difference between the load bearing alloys and the coating surface. In doing so,

these coatings can allow for higher operating temperatures while limiting the thermal exposure

of structural components, extending part life by reducing oxidation and thermal fatigue.

In fact, in conjunction with active film cooling, Thermal barrier coatings permit flame

temperatures higher than the melting point of the metal airfoil in some turbine applications.

Modern Thermal barrier coatings are required to not only limit heat transfer through the coating

but to also protect engine components from oxidation and hot corrosion. No single coating

composition appears able to satisfy these multifunctional requirements. As a result, a “coating

system” has evolved. Research in the last 20 years has led to a preferred coating system

consisting of three separate layers such as metal substrate, bond coat and ceramic coating to

achieve long term effectiveness in the high temperature, oxidative and corrosive use

environment for which they are intended to function. The application of Thermal barrier

coatings on the diesel engine piston head reduces the heat loss to the engine cooling-jacket

through the surfaces exposed to the heat transfer such as cylinder head, liner, piston crown and

piston rings. It is important to calculate the piston temperature distribution in order to control

the thermal stresses and deformations within acceptable levels. The temperature distribution

enables the designer to optimize the thermal aspects of the piston design at lower cost, before

the first prototype is constructed. As much as 60% of the total engine mechanical power lost is

generated by piston ring assembly.

The metal substrate is typically a high temperature aluminum alloy that is either in single

crystal or polycrystalline form. The metallic bond coat is an alloy typically with the composition

of Nickel, Cobalt, Chromium, Aluminum. The bond coat creates a bond between the ceramic

coat and substrate. The third coat is the ceramic topcoat, Zirconia (ZrO2), Mullite (3Al2O3-

2SiO2), Alumina (Al2O3) which is desirable for having very low conductivity while remaining

stable at nominal operating temperatures typically seen in applications.

This layer creates the largest thermal gradient of the thermal barrier coating. In industry,

thermal barrier coatings are produced in a number of ways.

• Electron Beam Physical Vapor Deposition (EBPVD).

• Air Plasma Spray (APS).

• Electrostatic Spray Assisted Vapour Deposition (ESAVD).

• Direct Vapor Deposition.

Diesel engine piston made of Cast iron is taken for this study and ceramic material having

low thermal conductivity is preferred as the coating material on the piston head or crown.

M. Soundar, P. Anand and V. Ramesh


PROBLEM FORMULATION

A cursory look at the internal combustion engine heat balance indicates that the input energy is

divided into roughly three equal parts: energy converted to useful work, energy transferred to

coolant and energy lost to exhaust as a waste heat. The 20% of energy is lost due to heat, 30%

of energy is transferred to coolant and remaining 50% of energy is only converted to useful

work [3].The energy lost can be recovered by ceramic coating (Crown of the piston, side of the

cylinder liner, cylinder head )

Figure 1 Ceramic Coating

MATERIALS

ZIRCONIA (ZrO2)

Zirconium dioxide (ZrO2), sometimes known as zirconia (not to be confused with zircon), is a

white crystalline oxide of zirconium. Its most naturally occurring form, with

a monoclinic crystalline structure, is the mineral baddeleyite. A dopant stabilized cubic

structured zirconia, cubic zirconia, is synthesized in various colors for use as a gemstone and

a diamond stimulant. Zirconia can be found in three crystal structure as it can be seen in Fig.

4.1. These are monolithic (m), tetragonal (t) and cubic (c) structures. Monolithic structure is

stable between room temperature and 1170 °C while it turns to tetragonal structure above 1170

°C. Tetragonal structure is stable up to 2379 °C and above this temperature, the structure turns

to cubic structure.

Figure 2 Three Crystal Structure For ZrO2


Piston Head


Usually cracks and fractures are observed during changing phases because of 8% volume

difference while transition to tetragonal structure from monolithic structure. To avoid this and

make zirconia stable in cubic structure at room temperature, alkaline earth elements such as

CaO (calcium oxide), MgO (magnesia), Y2O3 (yttria) and oxides of rare elements are added to

zirconia. Zirconia based ceramic materials stabilized with yttria have better properties

comparing with Zirconia based ceramic materials which are stabilized by magnesia and calcium

oxide (Yaşar, 1997; Geçkinli, 1992). Mechanical properties of cubic structure zirconia are

weak. Transition from tetragonal zirconia to monolithic zirconia occurs at lower temperatures

between 850-1000 0C and this transition has some characteristics similar to martensitic

transition characteristics which are observed in tempered steels. In practice, partially stabilized

cubic zirconia (PSZ) which contains monolithic and tetragonal phases as sediments, is preferred

owing to its improved mechanical properties and importance of martensitic transition. Partially

stabilized zirconia has been commercially categorized since early 70s. Table 4.1 contains

partially stabilized zirconia types and their properties.

Structural properties of these materials are;

• Zt35: Contains 20% (t) phase in cubic matrix. Particle dimensions are about 60-70 μm.

• ZN40: Contains 40-50% (t) phase.

• ZN50: Particle dimensions are about 60-70 μm and a thin film (m) phase lays on the borders of

particles.

Table 1 Structural Properties

SPRAY COATING

Spray coating is the modern of coating. Here the solution is sprayed by using the nozzle, which

produce high pressure and atomizes the liquid or solution and gives the accurate coating over

the required surface.

TYPES OF SPRAY COATING

• Flame spray coatings

• Powder flame spray coatings

• Wire flame spray coatings

• Plasma spray coating

THERMAL IMAGE CAMERA

A Thermal Imaging Camera (colloquially known as a TIC) is a type of thermo graphic

camera used in firefighting. By rendering infrared radiation as visible light, such cameras

allow firefighters to see areas of heat through smoke, darkness, or heat-permeable barriers.



Thermal imaging cameras are typically handheld, but may be helmet-mounted. They are

constructed using heat- and water-resistant housings, and ruggedized to withstand the hazards

of fire ground operations. While they are expensive pieces of equipment, their popularity and

adoption by firefighters in the United States is increasing markedly due to the increased

availability of government equipment grants following the September 11 attacks in 2001.

Thermal imaging cameras pick up body heat, and they are normally used in cases where people

are trapped where rescuers cannot find them.

A thermal imaging camera consists of five components: an optic system, detector, amplifier,

signal processing, and display. Fire-service specific thermal imaging cameras incorporate these

components in a heat-resistant, ruggedized, and waterproof housing. These parts work together

to render infrared radiation, such as that given off by warm objects or flames, into a visible

light representation in real time. The camera display shows infrared output differentials, so two

objects with the same temperature will appear to be the same "color". Many thermal imaging

cameras use grayscale to represent normal temperature objects, but highlight dangerously hot

surfaces in different colors.

INFRARED THERMOMETER

An infrared thermometer is a thermometer which infers temperature from a portion of

the thermal radiation sometimes called blackbody radiation emitted by the object being

measured. They are sometimes called laser thermometers if a laser is used to help aim the

thermometer, or non-contact thermometers or temperature guns, to describe the device's ability

to measure temperature from a distance. By knowing the amount of infrared energy emitted by

the object and its emissivity, the object's temperature can often be determined. Infrared

thermometers are a subset of devices known as "thermal radiation thermometers". Sometimes,

especially near ambient temperatures, false readings will be obtained indicating incorrect

temperature. This is most often due to other thermal radiation reflected from the object being

measured, but having its source elsewhere, like a hotter wall or other object nearby - even the

person holding the thermometer can be an error source in some cases. It can also be due to an

incorrect emissivity on the emissivity control or a combination of the two possibilities.

The most basic design consists of a lens to focus the infrared thermal radiation on to

a detector, which converts the radiant power to an electrical signal that can be displayed in units

of temperature after being compensated for ambient temperature. This configuration facilitates

temperature measurement from a distance without contact with the object to be measured. As

such, the infrared thermometer is useful for measuring temperature under circumstances where

thermocouples or other probe type sensors cannot be used or do not produce accurate data for

a variety of reasons. Some typical circumstances are where the object to be measured is moving;

where the object is surrounded by an electromagnetic field, as in induction heating; where the

object is contained in a vacuum or other controlled atmosphere; or in applications where a fast

response is required, an accurate surface temperature is desired or the object temperature is

above the recommended use point for contact sensors, or contact with a sensor would mar the

object or the sensor, or introduce a significant temperature gradient on the object's surface.

Infrared thermometers can be used to serve a wide variety of temperature monitoring

functions.

A few examples provided to this article include:

• Detecting clouds for remote telescope operation.

• Checking mechanical equipment or electrical circuit breaker boxes or outlets for hot spots.

• Checking heater or oven temperature, for calibration and control purposes.


Piston Head


• Detecting hot spots / performing diagnostics in electrical circuit board manufacturing.

• Checking for hot spots in fire fighting situations.

• Monitoring materials in process of heating and cooling, for research and development or

manufacturing quality control situations

There are many varieties of infrared temperature sensing devices available today, including

configurations designed for flexible and portable handheld use, as well many designed for

mounting in a fixed position to serve a dedicated purpose for long periods. Specifications of

portable handheld sensors available to the home user will include ratings of temperature

accuracy (usually with measurement uncertainty of ±2 °C/±4 °F) and other parameters.

Figure 3 Infrared Thermometer Figure 4 Diesel Engine

The distance-to-spot ratio (D: S) is the ratio of the distance to the object and the diameter

of the temperature measurement area. For instance if the D:S ratio is 12:1, measurement of an

object 12 inches (30 cm) away will average the temperature over a 1-inch-diameter (25 mm)

area. The sensor may have an adjustable emissivity setting, which can be set to measure the

temperature of reflective (shiny) and non-reflective surfaces. A non-adjustable thermometer

sometimes can be used to measure the temperature of a shiny surface by applying a non-shiny

paint or tape to the surface, if the allowed measurement error is acceptable. The most common

infrared thermometers are the:

• Spot Infrared Thermometer or Infrared Pyrometer, which measures the temperature at a

spot on a surface (actually a relatively small area determined by the D:S ratio).

METHODS

ENGINE SPECIFICATION

We collect the data’s related to the diesel engine from the THIAGARAJAR COLLEGE OF

ENGINEERING, Madurai.

Table 2 Engine Specification



The Kirloskar, Vertical, Four stroke Diesel engine specifications shown. The design of this

engine in Pro-E is shown.

Figure 5 Dimensions of The Cylinder Head And Liner Figure 6 Piston Analysis

The analysis of the Cylinder without Ceramic Coating in ANSYS is shown below.

Figure 7 Piston Analysis Before Coating Figure 8 Piston Analysis After Coating

In the Fig 7 The temperature of 1200°C is given between Piston head and Cylinder liner it

is found that without Ceramic coating, the outer surface of the cylinder experiences a

temperature of 100°C. Here more heat loss takes place. We aimed to reduce the heat loss and

make it as a useful work by doing ceramic coating over the cylinder liner and piston head.

In the Fig 8 The temperature of 1200°C is given between Piston head and Cylinder liner it

is found that with 35 times spray (1mm) Ceramic coating, The outer surface of the cylinder

experiences a temperature of 10°C. Here less heat loss takes place. Here 90°C of heat is made

as useful work by doing ceramic coating over the cylinder liner and piston head.

METHODS

PRACTICAL METHODS

STEPS

• Selection of Cast iron bar

• Preparation of Zirconium oxide solution

• Coating of Cast iron bar

• Thermal Analysis

SELECTION OF CAST IRON BAR

Cast iron bar of 10×5×2 cm is used for coating with Zirconium oxide. This selected Cast iron

bar is heated and examined under thermal image camera.


Piston Head


Figure 9 Cast Iron Bar Figure 10 ZIR Conium Oxide Powder

PREPARATION OF ZIRCONIUM OXIDE SOLUTION

Zirconium Oxide is in powder form. It was bought from the chemical shop. It is made into

liquid form with some other mixtures to coat over the cast iron plate.

Composition of Zirconia

• Zirconium Oxide(ZrO2) - 97%

Impurities are

• Silicate(SiO2) - 0.25%

• Titanium(TiO2) - 0.16%

• Iron(Fe2O3) - 0.07%

SOLUTION PREPARATION

• 5gm of Zirconium Oxide

• 1gm of Zirconium Nitrate

• 150ml of Water

• 50ml of Ethanol

• 2ml of Tri ethanol amine

Mixing the above components at the mentioned quantities with the PH 10.

COATING

The solution must be mixed with the above mentioned ratio only. Because this ratio will give

the perfect mixture and it will perfectly settle over the cast iron plate. The mixture is spayed

over the cast iron bar. Before spraying the cast iron is heated at 250 °C. This temperature is

noted by using the infrared thermometer. Because only at this temperature the solution will

settle over the plate permanently. The solution is sprayed using powder flame spray coating.

The coating can be given with different sprays. Here we choose 15 sprays, 25 sprays, 35 sprays.

We can analyze the cast iron bar with these different sprays and the heat loss can be found.



Figure 11 Temperature Noted Using Infrared Thermometer

Figure 12 Uncoated Bar Figure 13 Sprays Coated Bar

Figure 14 Sprays Coated Bar Figure 15 Sprays Coated Bar

Figure 16 after Coating

THERMAL ANALYSIS

• Here the Cast iron bar is placed over the furnace and start heating the bar.

• The Solution prepared is kept ready for spraying over the bar.

• When the temperature of 250°C obtain the spray must done over the bar.


Piston Head


• There must be 3 bars chosen for the three different sprays 15, 25 and 35 sprays.

• After spraying the bar is allowed to cool at room temperature so that the solution set over the

bar permanently.

• Then the bar with coating of 15, 25 and 35 sprays and un coated bars are placed over the hot

plate.

• The hot plate is maintained at 150°C for 15mins.

• Then the Cast iron bars are placed over hot plate.

• Now the temperature distributions are noted by using the thermal image camera and the

temperature variations are noted down for all bars.

RESULT AND DISCUSSION

IMAGE CAPTURE BY USING FLIR E60 THERMAL IMAGE CAMERA

Figure 17 Thermal Image Capture for Uncoated and 15 Times Spray Bar

Figure 18 Thermal Image Capture For 25 And 35 Times Spray Bar

Initially an uncoated & 15 times spray cast iron bar is placed on the hot plate, then a hot

plate heated up to 150°C. Maintained a heat for 15 mins. Then take a capture by using FLIR

E60 thermal image camera. The fig 7.1 shown the temperature difference from uncoated bar to

15 times spray cast iron bar.

From the Thermal image camera it is noted that

• Uncoated cast iron bar – 91.0°C

• 15 times Spray Cast iron bar – 86.3°C





CONCLUSION

Cast iron has wide range of applications in various field due to its property, one of its special

application is in automobile field and engine parts. Due to higher thermal property the cast iron

is used in engines also. They are used to manufacture cylinder liners and piston head. There is

always high temperature of about 1200°C. There was heavy heat loss takes place at the outer

surface of the engine. This heat loss should be reduced and change into the useful work by some

criteria. We analyzes the cylinder of the Kirloskar, Vertical, Four stroke Diesel engine, using

ANSYS. First we analyze the cylinder without coating here we gave 1200°C, we found that at

the outer surface of the cylinder there is 100°C. But when analyzing the cylinder with 1mm

coating of zirconium oxide at 1200°C the result shows that the outer surface of the cylinder

only 10°C. There is 90°C of heat is made into useful work.

In the experimental analysis using thermal image camera, the Zirconium Oxide is coated

over the cast iron bar and analyzed. We are Heating the bar of 150°C, It is noted that 35 times

spray bar (69.6°C) was more efficient than 25(74.8°C) and 15(86.3°C) times spray and

uncoated (91°C). But when the spray times exceed more than 35, then the thickness of coating

increased over 1mm. So, the coating must be at 35 sprays.

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Documents

IMPROVING THERMAL EFFICIENCY OF DIESEL ENGINE BY USING … · 2017-07-26 · A dopant stabilized cubic structured zirconia, cubic zirconia, is synthesized in various colors for use