CiteExportLink to record
Permanent link

Direct link
Cite
Citation style
  • apa
  • harvard1
  • ieee
  • modern-language-association-8th-edition
  • vancouver
  • Other style
More styles
Language
  • de-DE
  • en-GB
  • en-US
  • fi-FI
  • nn-NO
  • nn-NB
  • sv-SE
  • Other locale
More languages
Output format
  • html
  • text
  • asciidoc
  • rtf
Thermal Barrier Coatings for Heavy-Duty Diesel Engines
KTH, School of Industrial Engineering and Management (ITM), Machine Design (Dept.). Scania CV AB.ORCID iD: 0000-0002-3423-8688
2019 (English)Doctoral thesis, comprehensive summary (Other academic)
Place, publisher, year, edition, pages
Stockholm: KTH Royal Institute of Technology, 2019. , p. 63
Series
TRITA-ITM-AVL ; 2019:36
Keywords [en]
Thermal barrier coatings, diesel engine, thermal cycling fatigue, heat flux, running-in, exhaust manifolds, yttria-stabilized zirconia, gadolinium zirconate, lanthanum zirconate
National Category
Vehicle Engineering
Research subject
Machine Design
Identifiers
URN: urn:nbn:se:kth:diva-263116ISBN: 978-91-7873-347-7 (print)OAI: oai:DiVA.org:kth-263116DiVA, id: diva2:1366544
Public defence
2019-11-29, Gladan (B319), Brinellvägen 85, Stockholm, 10:00 (English)
Opponent
Supervisors
Available from: 2019-10-31 Created: 2019-10-29 Last updated: 2019-10-31Bibliographically approved
List of papers
1. Evaluation of internal thermal barrier coatings for exhaust manifolds
Open this publication in new window or tab >>Evaluation of internal thermal barrier coatings for exhaust manifolds
Show others...
2015 (English)In: Surface & Coatings Technology, ISSN 0257-8972, E-ISSN 1879-3347, Vol. 272, p. 198-212Article in journal (Refereed) Published
Abstract [en]

Seven different thermal barrier coatings (TBC) intended for coating the inside of an exhaust manifold to reduce its material temperature were studied. They comprised five plasma-sprayed (mullite, forsterite, La2Zr2O7, 8YSZ, and nanostructured 8YSZ) and two sol-gel composite (one sprayed and one dipped) coatings, which were examined for their thermal insulation properties and oxidation and spallation resistance. Thermal cyclic tests in air and in exhaust gas in a diesel test engine showed that thermal expansion mismatch between substrate and TBC was most crucial for TBC lifetime. Moreover, thermal modeling indicated that it is possible to reduce the material temperature by 50°C, which is important for improving the fatigue life of exhaust manifolds. This reduction can be obtained with a 0.2mm thick TBC with thermal conductivity close to 0.1W/m K, or a 3–6mm thick TBC with thermal conductivity 1.5–3W/m K.

Keywords
Exhaust manifold, SiMo51, Thermal barrier coating, Sol-gel composite, Plasma-sprayed coatings, Thermal modeling
National Category
Vehicle Engineering
Research subject
Machine Design
Identifiers
urn:nbn:se:kth:diva-263111 (URN)10.1016/j.surfcoat.2015.04.005 (DOI)
Available from: 2019-10-29 Created: 2019-10-29 Last updated: 2019-10-29
2. A test rig for evaluating thermal cyclic life and effectiveness of thermal barrier coatings inside exhaust manifolds
Open this publication in new window or tab >>A test rig for evaluating thermal cyclic life and effectiveness of thermal barrier coatings inside exhaust manifolds
2019 (English)In: SAE technical paper series, ISSN 0148-7191, Vol. 2019-April, no AprilArticle in journal (Refereed) Published
Abstract [en]

Thermal Barrier Coatings (TBCs) may be used on the inner surfaces of exhaust manifolds in heavy-duty diesel engines to improve the fuel efficiency and prolong the life of the component. The coatings need to have a long thermal cyclic life and also be able to reduce the temperature in the substrate material. A lower temperature of the substrate material reduces the oxidation rate and has a positive influence on the thermo-mechanical fatigue life. A test rig for evaluating these properties for several different coatings simultaneously in the correct environment was developed and tested for two different TBCs and one oxidation-resistant coating. Exhausts were redirected from a diesel engine and led through a series of coated pipes. These pipes were thermally cycled by alternating the temperature of the exhausts. Initial damage in the form of cracks within the top coats of the TBCs was found after cycling 150 times between 50°C and 530°C. Temperature calculations showed that, besides evaluating the thermal cyclic life, the test method has the potential to provide a quick ranking of coating materials with respect to thermal insulation by measuring the temperature on the outer surface of the coated pipes. One of the major advantages of the presented test method compared to other methods described in the literature is that it ranks the thermal cyclic life and thermal properties of different coatings under realistic conditions in the correct environment. More cycles and higher temperatures are recommended for future tests, to accelerate the test, as well as evaluate whether the initial cracks in the TBCs will lead to spallation.

Place, publisher, year, edition, pages
SAE International, 2019
Keywords
Automobile engine manifolds, Coated materials, Cracks, Diesel engines, Exhaust manifolds, Oxidation resistance, Thermal fatigue, Thermal insulation, Heavy-duty diesel engine, Lower temperatures, Oxidation resistant coating, Realistic conditions, Substrate material, Temperature calculation, Thermal barrier coating (TBCs), Thermo mechanical fatigues (TMF), Thermal barrier coatings
National Category
Manufacturing, Surface and Joining Technology
Identifiers
urn:nbn:se:kth:diva-255936 (URN)10.4271/2019-01-0929 (DOI)2-s2.0-85064705377 (Scopus ID)
Conference
9 April 2019 through 11 April 2019, SAE World Congress and Experience, Detroit, Michigan
Note

QC 20190816

Available from: 2019-08-16 Created: 2019-08-16 Last updated: 2019-11-26Bibliographically approved
3. Influence of microstructure on thermal cycling lifetime and thermal insulation properties of yttria-stabilized zirconia thermal barrier coatings for diesel engine applications
Open this publication in new window or tab >>Influence of microstructure on thermal cycling lifetime and thermal insulation properties of yttria-stabilized zirconia thermal barrier coatings for diesel engine applications
2018 (English)In: Surface & Coatings Technology, ISSN 0257-8972, E-ISSN 1879-3347, Vol. 350, p. 1-11Article in journal (Refereed) Published
Abstract [en]

Thermal barrier coatings (TBCs) may improve the fuel efficiency of heavy-duty diesel engines by reducing heat losses. A combination of durability, low thermal conductivity, and high directional hemispherical reflectance is required for a TBC in the combustion chamber. These properties are evaluated for yttria-stabilized zirconia coatings, produced using atmospheric plasma spraying (APS) and plasma spray–physical vapour deposition (PS-PVD). The influences of different types of microstructure and metallic coatings on the surface are studied. APS coatings with segmentation cracks and PS-PVD coatings with columnar microstructure have the best thermal cycling lifetime, while nanostructured and conventional APS coatings have the lowest thermal conductivities. The nanostructured APS coating has the highest reflectance at low temperatures, while the columnar PS-PVD coating has the highest reflectance at elevated temperatures. It is further demonstrated that a thin silver layer improves the reflectance of a dense, segmented APS YSZ coating.

Place, publisher, year, edition, pages
Elsevier, 2018
Keywords
Thermal barrier coatings, Thermal cycling lifetime, Hemispherical reflectance, Thermal conductivity, Diesel engine, Yttria-stabilized zirconia
National Category
Vehicle Engineering
Identifiers
urn:nbn:se:kth:diva-263110 (URN)10.1016/j.surfcoat.2018.07.005 (DOI)000444660500001 ()2-s2.0-85049423597 (Scopus ID)
Note

QC 20191126

Available from: 2019-10-29 Created: 2019-10-29 Last updated: 2019-11-26Bibliographically approved
4. Running-in behaviour of thermal barrier coatings in the combustion chamber of a diesel engine
Open this publication in new window or tab >>Running-in behaviour of thermal barrier coatings in the combustion chamber of a diesel engine
2019 (English)In: Proceedings of the Institution of mechanical engineers. Part D, journal of automobile engineering, ISSN 0954-4070, E-ISSN 2041-2991Article in journal (Refereed) Published
Abstract [en]

Thermal barrier coatings have the potential to improve the fuel efficiency of heavy-duty diesel engines by reducing heat losses. A method for in-situ measurement of heat flux from the combustion chamber of a heavy-duty diesel engine has been developed and was used to study the running-in behaviour of different thermal barrier coating materials and types of microstructures. The in-situ measurements show that the initial heat flux was reduced by up to 4.7% for all investigated thermal barrier coatings compared to a steel reference, except for an yttria-stabilized zirconia coating with sealed pores that had an increase of 12.0% in heat flux. Gd2Zr2O7 had the lowest initial value for heat flux. However, running-in shows the lowest values for yttria-stabilized zirconia after 2?3?h. Potential spallation problems were observed for Gd2Zr2O7 and La2Zr2O7.

Place, publisher, year, edition, pages
IMECHE, 2019
Keywords
Thermal barrier coatings, heat flux, diesel engine, combustion chamber, running-in
National Category
Vehicle Engineering
Research subject
Machine Design
Identifiers
urn:nbn:se:kth:diva-263113 (URN)10.1177/0954407019841173 (DOI)
Note

QC 20191111

Available from: 2019-10-29 Created: 2019-10-29 Last updated: 2019-11-11Bibliographically approved
5. A study of suspension plasma-sprayed insulated pistons evaluated in a heavy-duty diesel engine
Open this publication in new window or tab >>A study of suspension plasma-sprayed insulated pistons evaluated in a heavy-duty diesel engine
2019 (English)In: International Journal of Engine Research, ISSN 1468-0874, E-ISSN 2041-3149Article in journal (Refereed) Published
Abstract [en]

Thermal barrier coatings can be used to reduce the heat losses in heavy-duty diesel engines. A relatively new coating method for thermal barrier coatings is suspension plasma-spraying. Single-cylinder engine tests have been run to evaluate how heat losses to piston, cylinder head and exhausts as well as the specific fuel consumption are influenced by coating pistons with two different suspension plasma-sprayed thermal barrier coatings and one atmospheric plasma-sprayed thermal barrier coating, and comparing the results to those from an uncoated steel piston. The two suspension plasma-sprayed thermal barrier coatings showed reduced heat losses through the piston and less heat redirected to the cylinder head compared to conventional atmospheric plasma-sprayed thermal barrier coating, while one suspension plasma-sprayed coating with yttria-stabilized zirconia as top coat material showed increased exhaust temperature. However, the indicated specific fuel consumption was higher for all tested thermal barrier coatings than for an uncoated engine. The best performing thermal barrier coating with respect to indicated specific fuel consumption was a suspension plasma-sprayed coating with gadolinium zirconate as top coat material.

Keywords
Thermal barrier coatings, diesel engine, suspension plasma spray, heat losses, engine efficiency
National Category
Vehicle Engineering
Research subject
Machine Design
Identifiers
urn:nbn:se:kth:diva-263115 (URN)10.1177/1468087419879530 (DOI)000491790800001 ()
Note

QC 20191108

Available from: 2019-10-29 Created: 2019-10-29 Last updated: 2019-11-08Bibliographically approved

Open Access in DiVA

fulltext(4462 kB)29 downloads
File information
File name FULLTEXT01.pdfFile size 4462 kBChecksum SHA-512
21ac55cf4adedbed02f6b289a8febe137ebd5479968dc23e7b2ef5d646a0f16a8ea49db1515718422e8e3a5bd4e8ef36d6a87026fdb9f1ea1dbd45b205595810
Type fulltextMimetype application/pdf

Search in DiVA

By author/editor
Thibblin, Anders
By organisation
Machine Design (Dept.)
Vehicle Engineering

Search outside of DiVA

GoogleGoogle Scholar
Total: 29 downloads
The number of downloads is the sum of all downloads of full texts. It may include eg previous versions that are now no longer available

isbn
urn-nbn

Altmetric score

isbn
urn-nbn
Total: 292 hits
CiteExportLink to record
Permanent link

Direct link
Cite
Citation style
  • apa
  • harvard1
  • ieee
  • modern-language-association-8th-edition
  • vancouver
  • Other style
More styles
Language
  • de-DE
  • en-GB
  • en-US
  • fi-FI
  • nn-NO
  • nn-NB
  • sv-SE
  • Other locale
More languages
Output format
  • html
  • text
  • asciidoc
  • rtf