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<p>Improving the thermodynamic performance of internal combustion IC engines enhances efficiency, reduces emissions, and decreases fuel consumption by converting more fuel energy into mechanical work. The application of thermal barrier coatings (TBCs), particularly ceramic-based ones like yttria-stabilized zirconia (YSZ), allows for higher combustion chamber temperatures and more complete fuel combustion. These advancements lead to increased brake thermal efficiency, reduced specific fuel consumption, and enhanced engine power. Moreover, TBCs facilitate lighter engine designs by minimizing the need for extensive cooling systems. They also improve the longevity of engine components by protecting them from heat stress and lowering internal friction, both of which contribute to reduced emissions. This work aimed to improve the performance of the pistons in an engine with the help of TBC. Using 3DEXPERIENCE software, the piston was designed in a way that possessed a special thickness range for its crown (0.2–1&#xa0;mm). The main focus was on the structural and thermal analysis of the TBC pistons. The presence of unburnt hydrocarbons in exhaust gases leads to pollution, often due to heat loss in the combustion chamber. However, this heat loss can be prevented by using a TBC on the engine's piston crown. This paper discusses various TBC materials, their properties, and their impact on the performance of internal combustion (IC) engines. Two materials were used for the TBC, and they were YSZ and zirconium dioxide (ZrO<sub>2</sub>). Heat transfer analyses were carried out with 0.25&#xa0;mm YSZ and 0.45&#xa0;mm ZrO<sub>2</sub> materials for the piston. For YSZ and ZrO<sub>2</sub>, numerical analyses have been performed at thicknesses ranging from 0.25 to 1.0&#xa0;mm. The results were graphically plotted, and they showed that ZrO<sub>2</sub> outperformed in terms of thermal distribution and total heat flux.</p>

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Experimental studies and computational investigation on the enhancement of thermodynamic performance of IC engine piston using thermal barrier coating

  • 期刊论文

  • 发表日期：

    2025年9月11日

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  • Surya Balusamy,
  • Arul Prakash Raji,
  • Laxana Sourirajan,
  • Gopinath Vinayagam,
  • Sundhar Baskar,
  • Mamdooh Alwetaishi,
  • Beena Stanislaus Arputharaj,
  • Parvathy Rajendran,
  • Vijayanandh Raja,
  • Arunkumar Karuppasamy

摘要

Improving the thermodynamic performance of internal combustion IC engines enhances efficiency, reduces emissions, and decreases fuel consumption by converting more fuel energy into mechanical work. The application of thermal barrier coatings (TBCs), particularly ceramic-based ones like yttria-stabilized zirconia (YSZ), allows for higher combustion chamber temperatures and more complete fuel combustion. These advancements lead to increased brake thermal efficiency, reduced specific fuel consumption, and enhanced engine power. Moreover, TBCs facilitate lighter engine designs by minimizing the need for extensive cooling systems. They also improve the longevity of engine components by protecting them from heat stress and lowering internal friction, both of which contribute to reduced emissions. This work aimed to improve the performance of the pistons in an engine with the help of TBC. Using 3DEXPERIENCE software, the piston was designed in a way that possessed a special thickness range for its crown (0.2–1 mm). The main focus was on the structural and thermal analysis of the TBC pistons. The presence of unburnt hydrocarbons in exhaust gases leads to pollution, often due to heat loss in the combustion chamber. However, this heat loss can be prevented by using a TBC on the engine's piston crown. This paper discusses various TBC materials, their properties, and their impact on the performance of internal combustion (IC) engines. Two materials were used for the TBC, and they were YSZ and zirconium dioxide (ZrO2). Heat transfer analyses were carried out with 0.25 mm YSZ and 0.45 mm ZrO2 materials for the piston. For YSZ and ZrO2, numerical analyses have been performed at thicknesses ranging from 0.25 to 1.0 mm. The results were graphically plotted, and they showed that ZrO2 outperformed in terms of thermal distribution and total heat flux.