Lab Evaluation of YSZ Coating Surface

and Thermal Analysis for Plasma

Sprayed Coated IC Engine Piston

Presented by: Under the Guidance of:

Vaibhav Kumar Banka Dr. M. R. Ramesh
(15MF11F) Assistant Professor
Dept. of Mechanical
Engg.
NITK, Surathkal
 CONTENTS
• Literature Survey
• Principle of Thermal Spraying
• Methodology
• Finite Element Modeling
• Thermal Analysis
• Result and Discussion
• Conclusions
• References
 LITERATURE SURVEY

Input energy of an IC engine

• Energy used by coolant
• Energy which is utilized for useful work
• Energy lost through exhaust

• To improve the performance of an IC engine a technology

of insulating the piston, combustion chamber, and valve's
surfaces with TBC materials has been introduced.
Thermal Barrier Coating:
• Thermal fatigue protection
• Reduces heat rejection
• Protects piston from corrosion attack,
thermal stress, high heat emissions and it
reduces heat flux.
• TBC allows using low quality fuels by making
the piston temperature much higher than
uncoated one due to which proper
combustion of fuel occurs.
• TBC mainly consists three layers of
substrate, bond coat and top coat
 Coating Material: Yittria Stabilized
Zirconia
Yttria-stabilized zirconia (YSZ) is a ceramic in which the
crystal structure of zirconium dioxide is made stable at room
temperature by an addition of yttrium oxide. These oxides
are commonly called "zirconia" (ZrO2) and "Yttria" (Y2O3),
hence the name.

Fig.1-Yittria stabilized zirconia formation

 Bond Coat : NiCrAl
• Bond coat is used to provide bonding between
substrate and top coat surface.
• It also helps to reduces stresses occurring
during thermal shock.
• Corrosion resistance
 PRINCIPLE OF THERMAL SPRAYING

• Thermal spraying can provide thick coatings over

a large area at high deposition rate as compared
to other coating processes

• Plasma spraying
• Detonation spraying
• Flame spraying
• High velocity oxy-fuel coating (HVOF)
• High velocity air fuel (HVAF)
 Plasma Spraying

Fig.2-Schematic diagram of plasma spraying

 METHODOLOGY
• Define the material properties
• Modeling of the piston
• Meshing
• Apply boundary conditions
• Result analysis
 Material properties
Material Thermal Thermal Specific Modulus Poisson’s
conductivity expansio heat [J/ of ratio
[w/m°C] n in 10-6 kg °C] elasticity
[1/°C] (GPa)

Piston 155 23 910 71 0.33

(aluminum
alloy)
Rings (cast 58 12 460 200 0.30
iron)
Bond coat 16 12 764 90 0.27
Y-PSZ 1.4 10.9 620 46 0.20

Table -1: Material Property [1]

 FINITE ELEMENT MODELING

• Software: UG NX 10.0
• Bore -90mm
• Stroke length:120mm
• Engine rating :300 kW
• at 1500 rev/min
• Compression Ratio: 19:1
Fig -3: Piston model
Four 3 mm
Piston rings

Fig -4: Piston model

 THERMAL ANALYSIS
A thermal analysis was performed to determine the
temperature distribution and thermal stresses for
uncoated and coated piston which will be compared
with the coated surface with air holes for
performance improvement.
• Import model
• Assign material to each part
• Make connections
• Meshing setup and Meshing
Fig-5: Meshed model
Boundary Condition
• Convection is taken as a major phenomenon of heat
transfer in the piston. Different temperature and heat
transfer coefficient are applied to the different areas of
piston which is calculated using
Hohenberg Equation:
• hgas(t)=αVC(t) -0.06P(t)0.8T(t) -0.4 (s+b) 0.8

• Before applying the boundary conditions, some assumptions are made:

• The effect of piston motion on the heat transfer is neglected.
• The rings do not twist.
• The rings and skirt are fully engulfed in oil and there is no cavitation.
• The conductive heat transfer in oil film is neglected.
 Region Heat transfer Temperature
coefficient [w/m 2 [°C]
°C]

1 700 700

2 500 225

3 400 180

4 400 170

5 400 160

6 400 200

7 400 180

8 400 160

9 400 140

10 1500 110

11 1500 110

Table -2: Convection boundary

Fig-6: Thermal boundary region
conditions [1]
THERMAL BARRIER AND THERMAL SHOCK
TESTS

• The thermal barrier test involved exposing the ceramic coated

surface with a high temperature flame focused on the centre of the
coated specimen, allowing the ceramic surface sufficient time (~ 2
hours) to attain the intended stabilized temperature under the
steady flame conditions (flame temperatures (T) varying from 250
up to 650°C, (at regular ∆T of ~100 degrees).
THERMAL BARRIER AND THERMAL SHOCK
TESTS
• The thermal shock test involved exposing the ceramic surface
to 650°C for a pre-fixed amount of time (5 minutes) and
suddenly withdrawing the specimen to face a blast of cold air
to rapidly quench the hot ceramic surface including the
aluminium substrate; thereafter reintroducing the ceramic
surface to the flame after five minutes hold at the relatively
colder ambient.
 Result and Discussion
1) Temperature distribution for uncoated part and
coated part
Substrate Surface Temperature Distribution
for YSZ coated piston
Top and Substrate surface temperature distribution
for coated surface with 2-mm diameter holes
Top and Substrate surface temperature distribution
for coated surface with 3-mm diameter holes
Top and Substrate surface temperature distribution
for coated surface with 4-mm diameter holes
Top and Substrate surface temperature distribution
for coated surface with 5-mm diameter holes
 Result Table
Temperature distribution of piston top and substrate surface with various
design conditions [°C].

Type Top surface Temperature(◦ Substrate Temperature (◦

C) C)
Uncoated piston 359 --
Coated Piston 393 332
Coated piston with hole 420 313
(d=2mm)
Coated piston with hole 401 310
(d=3mm)
Coated piston with hole 393 305
(d=4mm)
Coated piston with hole 370 299
(d=5mm)
Temperature vs radius curve for top and
substrate surface

Top surface temperature Substrate temperature

420
400
Temperature (◦ C)

380
360
340
320
300
280
260
2 3 4 5
Radius (mm)
Thermal Stress Distribution for the
Uncoated and Coated surface
Thermal stress distribution for coated
surface with 2-mm diameter holes Thermal stress distribution for coated
surface with 3-mm diameter holes
Thermal stress distribution for coated
surface with 4-mm diameter holes Thermal stress distribution for coated
surface with 4-mm diameter holes
Table -4: Thermal stress distribution for piston surface with various design
conditions [MPa]

Type Substrate Max. Stress (MPa) Min. Stress (MPa)

Temperature (◦ C)
Uncoated piston 359 2239.8 17.46
Coated Piston 332 1712.6 5.36
Coated piston with 313 1206.6 14.98
hole (d=2mm)
Coated piston with 310 1202.5 14.87
hole (d=3mm)
Coated piston with 305 1191.8 14.77
hole (d=4mm)
Coated piston with 299 1156 14.69
hole (d=5mm)
 Thermal Barrier Test and Thermal Shock
Test
Drop in Temperature across TBC coated Substrate
140
126
117
120
Temperature diffrence

100 90
86
80 75

60 Temperature Diffrence

40

20

0
250 350 450 550 650
High Temperature
 CONCLUSIONS
• Analysed and test results clearly show that on applying YSZ coating
there is an increase in temperature of the top surface whereas
there is a decrease in temperature of the substrate.
• There is a further increase in temperature of top surface when
holes are created on the coating surface, i.e. 9.5% increase for
coated surface with 2 mm diameter holes whereas substrate
temperature is decreased by 2.7%.
• For coated surface with 2 mm diameter holes, efficiency is highest
(See Chart 1) as top surface temperature obtained is maximum
while for coated surface with 5 mm diameter holes has least
thermal fatigue.
• Thermal stress produced for the uncoated piston is the highest i.e.
2240 MPa which is 527 MPa higher than the coated piston and also
it keeps on decreasing on increasing the diameter of the holes on
the coating surface.
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THANK YOU