Effect of Piston Crown Thermal Barrier Coating on Performance and Emission Characteristics in Petrol Engine

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1 Effect of Piston Crown Thermal Barrier Coating on Performance and Emission Characteristics in Petrol Engine H. S. Patil 1, D. C. Patel 2, C. S. Patil 3 1 Professor, Mechanical Department, GIDC Degree Engineering College, Abrama, Gujarat, India 2 Associate Professor, Mechanical Department, GIDC Degree Engineering College, Abrama, Gujarat, India 3 Assist Professor, Mechanical Department, S. S. Agrawal Institute of Engg. & Tech., Navsari, Gujarat, India Abstract Now days a major problem of pollutions are due to exhaust emission of vehicles. With an increase in population and living standard, the transport vehicles as well as car population is increasing day by day. In addition to this there is steep increase in the number of two wheelers during the last two decades. All these are increasing exhaust pollution and affect the health of living beings, causing ozone layer depletion, greenhouse effect. The desire to reach higher efficiencies, lower specific fuel consumption and reduced emissions in modern engines has become the primary focus of engine researches and manufacturers over the past three decades. Ceramic coating is a solution to such problems as they provide good thermal barrier properties for designers. In the design of adiabatic engines, reducing in-cylinder heat rejection requires very special thermal barrier coatings on the engine combustion chamber. This study present the effect of coating on top of the piston on performance of three cylinder four stroke petrol engine and emission characteristics of exhaust gas. In this study Yttria Stabilized Zirconia (YSZ) is used as the thermal barrier coating material on the top of the piston crown by the plasma spraying process. Keywords : Piston crown YSZ coating, TBC Engine, engine performance and emission; I. INTRODUCTION Currently numerous investigation programs, in automotive industries, are carrying out in order to decrease engine fuel consumption and pollution. According to the First law of thermodynamics, thermal energy is conserved by reducing the heat flow to the cooling and exhausts systems. It s known that only one third of energy is converted into useful work, theoretically if rejection of heat is reduced then the thermal efficiency likely to be increased to a considerable extend. Energy conservation and efficiency have always been the quest of engineers concerned with internal combustion engines. 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 100µm to 2mm 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 [1]. A typical TBC system consists of (i) the top coat (TC), a porous ceramic layer that acts as the insulator, (ii) the bond coat (BC), an oxidation-resistant metallic layer between the substrate and the TC and (iii) the super alloy or other material substrate that carries the structural load [2]. Thermal barrier coatings (TBCs) have been successfully applied to the internal combustion engine, in particular the combustion chamber, to simulate adiabatic engines. The objectives are not only for reduced in-cylinder heat rejection and thermal fatigue protection of underlying metallic surfaces, but also for possible reduction of engine emissions. The application of TBC 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. The insulation of the combustion chamber with ceramic coating affects the combustion process and hence the performance and DOI: /IJRTER WBH5E 74

2 exhaust emissions characteristics of the engines [3]. Normally, in diesel engines about % of fuel energy is rejected to coolant fluid. Using TBC can reduce this heat loss and lead to better thermal efficiency. Also engine components durability can be improved. Therefore, better combustion, lower pollution, higher thermal efficiency and good fatigue lifetime are the results of using proper TBC in engine combustion chamber and exhaust system. The diesel engine with its combustion chamber walls insulated by ceramics is referred to as LHR engine. Thermal barrier coatings (TBC) are used to improve reliability and durability of hot section metal components and enhance engine performance and thermal efficiency and elimination of the cooling system in diesel engines. Thermal Barrier Coatings (TBCs) in petrol engines lead to advantages including higher power density, fuel efficiency, and multi fuel capacity due to higher combustion chamber temperature. Using TBC can increase engine power and decrease the specific fuel consumption and increase the exhaust gas temperature. Although several systems have been used as TBC for different purposes, yttria stabilized zirconia has received the most attention. Several important factors are playing important roles in TBC lifetimes including thermal conductivity, thermal, chemical stability at the service temperature, high thermos-mechanical stability to the maximum service temperature and the thermal expansion coefficient (TEC) [4]. The Application of TBC decreases the heat transfer to the cooling and exhaust system which ultimately results in the high temperature gas and high temperature combustion chamber wall which reduces the level of smoke and hydrocarbon (HC) emission. In particular, for the latter, durability concerns for the materials and components in the engine cylinders, which include piston, rings, liner, and cylinder head, limit the allowable in-cylinder temperatures. The application of thin TBCs to the surfaces of these components enhances high temperature durability by reducing the heat transfer and lowering temperatures of the underlying metal. Dr.Ibtihal et al. applying ceramic coating of 0.5µm in intake and exhaust valve of diesel engine and observed 7.6% reduction of BSFC that causes the conversion of additional heat energy in cylinder into useful work and also reduction in Exhaust emission gases of 13.2% for HC and 14.5% CO[5]. Mykola Bannikov coated VG combustion chamber by ZrO2 and MoSi2 and has been tested using the inhibition technique. Engine was tested before and after inhibition. The values measured were reduced to those of the test after inhibiting, i.e. to the base-line test. That NOx and CO emissions as well as exhaust opacity were significantly reduced due to in-cylinder catalytic coating at slightly improved fuel economy. The effect of coating on the NOx reduction increases with the load due to lower air-fuel ratio that provided more favourable condition for catalysis [6]. D. C. Gosai, H. J. Nagarsheth investigated experimentally on electroplated copper coated diesel engine for engine performance and exhaust emissions. Heat balance sheet indicates that heat use in brake power is improved about 1.7% due to copper coating engine. Heat lost by radiation and unaccounted losses are decreases by 4.3 %. At full load condition smoke density level is decrease about 2 % to %. HC level reduces by 1% to 9.1%, and NOx level reduced by 20.31% [7]. N. Nedunchezhian et al work out piston coating of copper catalyst which improves 10% fuel economy at 2 kw load condition and also HC emission levels reduced to a significant level [8]. Insulation of pistons in engines is reducing the heat losses and thus increasing the efficiency [9]. A major breakthrough in diesel engine technology has been achieved by the pioneering work done by Kamo et al [10]. Sekar and Kemo [11] developed an adiabatic engine for passenger cars and reported an improvement in performance to the maximum extent of 12%. Woschni et al. [12] state that 5% of the input fuel energy cannot be accounted for which is of the order of the expected improvements. Havstad et al. [13] developed a semi-adiabatic diesel engine and reported an improvement ranging from 5 to 9% in ISFC, about 30% reduction in the in-cylinder heat rejection. Prasad et al. [14] used thermally insulating material, namely partially stabilized zirconia (PSZ), on the piston crown face and reported a 19% reduction in heat loss through the piston. The major promises of thermal barrier coated engines were increased thermal efficiency and elimination of the cooling system. A simple first law of thermodynamics analysis of the All Rights Reserved 75

3 conversion process within a diesel engine would indicate that if heat rejection to the coolant was eliminated, the thermal efficiency of the engine could be increased. Thermal barrier coatings were used to not only for reduced in cylinder heat rejection and thermal fatigue protection of underlying metallic surfaces, but also for possible reduction of engine emissions. In this study thermal barrier coatings (TBC) is coated in piston crown with ceramic material Yttria stabilized zirconia (YSZ) which has low thermal conductivity, high resistance to erosion, corrosion and high thermal resistance, like This study present the effect of coating on top of the piston on performance of three cylinder four stroke petrol engine and emission characteristics of exhaust gas. II. EXPERIMENTAL METHODOLOGY The engine tests were conducted on a 3 cylinder four strokes, water cooled S.I. engine at constant speed 1300 rpm. The experimental set up of the engine with a rope brake dynamometers is shown in fig. 1. Two types of test were conducted namely uncoated piston test and coated piston test by the following procedure. The load as given as 2kg, 4kg and 6kg and readings were taken. For each load the time taken for 10CC of fuel was measured. The exhaust emission was measured by exhaust INDUS-5 make gas analyser model PEA205. Initially readings were taken on uncoated piston then after taking the readings, the engine parts were dismantled and piston top were coated with Yttria Stabilized Zirconia (YSZ) material. The uncoated and coated pistons crown is shown in figure 2.Thermal barrier coating of Yttria Stabilized Zirconia (YSZ) material was provided on the top of the piston crown with coating thickness of 200µm at coating temperature 2000K. The piston coating was carried out by plasma spraying process. The technical specification of Maruti Suzuki Omni engine and piston are shown in table- 1 and 2. Table 1 Specification Maruti Suzuki Omni engine Particulars Dimensions Engine 796cc l-3 No of cylinder 3 Bore 68.5mm Stroke 72.0mm Displacement 796(cc) Fuel system MPFI Compression ratio 8.8:1 Max power 34.7 PS (27bhp)@5000rpm Transmission 59Nm@2500rpm Figure 1 Experimental set up of the SI engine with a rope brake All Rights Reserved 76

4 Table 2 Specification of coated piston of SI Engine Particulars Dimensions Dia. of piston 56 mm Shank length 64 mm No. of ports 5 Pin dia. 14 mm No. of piston rings 2 Thickness of piston ring 1.5 mm Piston with YSZ Coating 200 micron Coating temperature 2000 K Figure 2 Uncoated and coated pistons crown of SI engine III. RESULTS AND DISCUSSION 3.1 Engine Performance The engine tests were conducted 3-cyinder petrol engine at a constant engine speed. After getting the stable operating condition experimentally, the engine was allowed to subject to variable loading condition. In experimental analysis zero load condition to various loading i.e. at 2 kg, 4 kg, 6 kg were considered. The experimental analysis was carried out for coated piston engine and non-coated piston engine. During the testing process data recorded for different performance parameters like brake power, fuel consumption, and brake thermal efficiency Brake Specific Fuel Consumption The variation of brake specific fuel consumption with engine load is shown in figure 3 for uncoated and thermal barrier coated engines. It can be observed from the results that thermal barrier coated in piston crown decreasing BSFC when compared with uncoated engine. This may be due to increased temperature of the piston crown which increases the temperature of cylinder wall and gas, which causes higher temperature in combustion chamber. The combustion conditions become more favourable which results shortening ignition delay time in coated engine affects the both chemical and physical reactions positively. It is believed that, this situation contributes to decrease BSFC when compared to uncoated engine. From the figure.3, it is clear that BSFC is high for low loads and it is decreasing when the load increases. Moreover same for coated and uncoated pistons, but at the higher loads a significant change in BSFC occurs in coated pistons. From the BSFC plot it is observed that 13.35% decrease in BSFC for piston coated engine compared to uncoated All Rights Reserved 77

5 Figure.3 Uncoated and coated pistons crown for various engine loads Brake Thermal Efficiency The variation of brake thermal efficiency with engine load is shown in figure 4 for uncoated and thermal barrier coated engines. It can be observed from the results that thermal barrier coating in piston crown improves the thermal efficiency when compared with uncoated engine. The ceramic coating has low thermal conductivity which enhances higher operating temperature of the engine. The thermal efficiency was increased due to the reduction in transfer of heat from the gas to the wall (piston crown) during the combustion or expansion. The variation of BTE in TBC engine depends upon the thermal conductivity of the material. From the efficiency plot it has been observed that brake thermal efficiency is increases 17.39% in the coated piston engine compared to uncoated engine. Figure.4 Brake Thermal Efficiency curve for various engine loads 3.2 Exhaust Emission Characteristics Due to incomplete combustion in the engine, there are a number of combustion products like HC, CO, NOx, etc. Hydrocarbons react in the presence of nitrogen oxides and sunlight to form All Rights Reserved 78

6 level ozone, a.major component of smog. Ozone irritates the eyes, damages the lungs, and aggravates respiratory problems. Nitrogen oxides, like hydrocarbons, are precursors to the formation of ozone. They also contribute to the formation of acid rain. Carbon monoxide reduces the flow of oxygen in the blood stream and is particularly dangerous to person with heart disease.carbon dioxide does not directly impact human health, but it is a greenhouse gas that traps the earth s heat and contributes to the potential for global warming. The emission characteristics like HC, CO2, CO, HC, O2 was analysed by using gas analyser and this result are discussed as under: HC Emission Characteristics The variation of HC emissions with engine load is shown in figure 5 for uncoated and thermal barrier coated piston. The unburned hydrocarbon emissions are reduced when the engine runs with coating. The unburned HC emissions are slightly higher when the engine runs without the coating. The main reason for this reduction in the unburned HC emissions is that at high temperatures the engine will have sufficient amount of oxygen which mixes with the HC emissions. As a result of this, the HC will split into H and C which mixes with O2, thereby reducing the HC emissions. The difference levels are approximately 90ppm to 71ppm for uncoated and coated piston engine respectively at high load. Figure.5 HC Emission Curve for various engine loads CO2 Emission Characteristics Figure 6 show CO2 emission curve for coated piston and without coated piston. The maximum value of CO2emission for 18.2 % and 21.7 % at 6 Kg load for without piston coating engine and piston coating engine respectively. The CO2 emission is 19.23% increase for piston coating engine. Due to high temperature HC spilt into H and C and this C combine with O2. Therefore emissions of CO2 All Rights Reserved 79

7 25 CO 2 EMISSSION 20 CO2, % WITHOUT COATING WITH COATING LOAD (W), kg Figure.6 CO2 Emission Curve for various engine loads CO Emission Characteristics The variation of CO emissions with load is shown in figure 7 for uncoated and thermal barrier coated engines. It can be observed from the results that thermal barrier coating in piston crown decreasing CO when compared with uncoated engine. CO is decreased after the coating due to the complete combustion. The carbon monoxide, which arises mainly due to incomplete combustion, is a measure of combustion in efficiency. At high temperature C easily combine with O2 and reduce CO emission, At without load condition CO emission is 2.5% for without coated piston and 1.1% for coated piston. And at high load condition CO emission is 1.1% for without coated piston and 0.6% for coated piston. Figure.7 CO Emission Curve for various engine loads O 2 Emission Characteristics Figure 8 shows O2 emission for coated piston and non-coated piston and it concluded that the O2 emission is increases with increasing in load. For coated piston O2 is easily combine C due to low heat losses. Therefore O2 emissions are decrease for coated piston engine compare to uncoated piston engine. O2 emission is 15.5% decrease for coated piston All Rights Reserved 80

8 Figure.8 O2 emission curve for various engine loads IV. CONCLUSION As the Yttria Stabilized Zirconia is a low thermal conductivity material, it reduces the heat losses from the engine piston to surrounding. Therefore the efficiencies are increase and the emissions are reduced because of various chemical reaction takes place inside the engine cylinder at high temperature. Brake thermal efficiency of coated piston is increase by the average value 17.39% compare to uncoated piston engine % reductions in brake specific fuel consumption were achieved with the coated piston % of HC emissions were reduce by using the coated piston. CO emissions are reducing by 45.45% because of at high temperature C easily combine with O2 and reduce CO emission. REFERENCES I. K. Sridhar1, R. Reji Kumar, M. Narasimha 'Thermal Barrier Analysis, international journal of modern II. III. engineering research,vol.3, issue may-june Sofia A. Tsipas,(2005) Thermophysical Properties of Plasma Sprayed Thermal Barrier Coatings thesis of University Of Cambridge, Department of Materials Science and Metallurgy. [ Siew Hwa Chan Performance and emissions characteristics of a partially insulated gasoline engine, ELSEVIER. (2000) IV. Ramesh B.Poola, B Nagalingam and K.V.Gopalakrishnan Performance of Thin-CeramicCoated Combustion Chamber with Gasoline and Methanol as Fuels in a Two-Stroke SI Engine. SAE Technical Paper , V. Dr. Ibtihal., Experimental and Computational Investigations on Piston Coated Externally Scavenged S.I. Engine ISOR for Journal of Mechanical and Civil Engineering. Jul-2013,pp-115 VI. Mykola Bannikov, The Influence of Thermal Barrier Coating Surface Roughness on Spark Ignition Engine Performance and Emissions Mechanical and Industrial Engineering University of Toronto VII. D. C. Gosai, H. J. Nagarsheth, Evaluation of Engine Performance and ExhaustEmission Characteristics of Copper Coated DieselEngine ISSN: , Volume-4 Issue-1, March 2015 VIII. N. Nedunchezhian, Effect on in-cylinder catalytic coating on the performance of a two-stoke spark ignition engine IJOEMS, Vol, 8 february 2001, pp.1-7 IX. T. Senthilkumar, experiment investigation of copper coating on piston ring ISOR for mechanical Engineering. April-2014, pp-5-7 X. R. Kamo, and W. Bryzik, Adiabatic turbo compound engine performance prediction. SAE Paper ; XI. R. Kamo, and W. Bryzik, Ceramics in heat engines. SAE Paper , XII. R.R. Sekar, and R. Kamo, Advanced adiabatic diesel engine for passenger cars. SAE Paper , XIII. G. Woschni,, W. Spindler, and K. Kolesa, Heat insulation of combustion chamber Walls A measure to decrease the fuel consumptionof I.C. Engines, SAE Paper ,1987. XIV. P.H. Havstad, IJ. Gervin, and WR. Wade, A ceramic insert uncooled diesel engine.sae Paper ; XV. R. Prasad, and N.K. Samria, Heat transfer and stress fields in the inlet and exhaust valves of a semiadiabatic diesel engine.computstruct 1990; 34(5):765 All Rights Reserved 81

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