A Review Study on Thermal Barrier Coatings for Diesel Engine Performance and Emission with Tribological Analysis

Kuldeep Singh; Om Prakash Jakhar; Mahesh Chand Saini

doi:10.29284/yzk14m43

Authors

Kuldeep Singh Department of Mechanical Engineering, Engineering College Bikaner, Bikaner, India
Om Prakash Jakhar Department of Mechanical Engineering, Engineering College Bikaner, Bikaner, India
Mahesh Chand Saini School of Engineering and Technology, Sandeep University, Nashik, India

DOI:

https://doi.org/10.29284/yzk14m43

Keywords:

Diesel Engine, Thermal Barrier Coating, Coating Material Characterization, Thermal Cycling Life, COF and Wear Rate, CFD Simulation, Brake Thermal Efficiency, BSFC and Emissions.

Abstract

In the automotive industry, enhancing diesel engine performance while simultaneously controlling exhausts emissions in compliance with environmental regulations has become increasingly important. The thermal barrier coatings applied on diesel engine combustion chamber parts is a promising approach to achieving these objectives. Based on the literature reviewed in this study, key parameters of TBC like as low thermal conductivity, low specific heat capacity, high melting point, high porosity, phase stability and high fracture toughness are considered in the selection of suitable ceramic coating materials. Numerous researchers have applied 8YSZ as upper layer and NiCrAlY as intermediate layer between top coat and substrate upto 500 μm thick in coating system by atmospheric plasma spray coating method. The reported results indicate increases the coated engine performance and improved exhaust emission except NO_x emission. The surface morphology of the coated system including porosity distribution, microcracks, and surface texture has been extensively examined by FE-SEM, Similarly the phase stability and elemental composition of coating system evaluated by XRD and EDS colour mapping respectively. Thermal cycling and microhardness evaluations have shown that the addition of Al₂O₃ whiskers, CeO₂, and other such oxides Nd₂O₃, Gd₂O₃, and Yb₂O₃ enhances coating durability by reducing thermally induced stresses between both coating layers, thereby extending coating life. Tribological experiments conducted on a piston–liner interface using an engine tribometer revealed a reduction in friction coefficient and wear rate for TBC-coated liners, indicating that the ceramic coating effectively promotes improved lubrication behavior. Furthermore, CFD based combustion chamber models validated with experimental results demonstrated increases combustion pressure and temperature with higher heat energy generated rate for coated engines compared to uncoated engines. Most experimental investigations reported that the reduction in heat loss through the cooling system due to TBC application gives higher brake thermal efficiency, less brake specific fuel consumption (BSFC), and higher side exhaust gas temperature. The exhaust gas emissions of coated engines consistently exhibited reduced HC, CO, and smoke opacity, although higher NOx emission found, primarily due to elevated combustion gas temperatures.

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