Performance analysis of IC engine with ceramic-coated piston.

Area of Science:

• Materials Science
• Mechanical Engineering
• Combustion Science

Background:

• Diesel engine components face thermal stress and efficiency challenges.
• Ceramic coatings offer potential for improved thermal management and performance.
• Yttria-stabilized zirconia is a promising material for thermal barrier coatings.

Purpose of the Study:

• To evaluate the impact of yttria-stabilized zirconia ceramic coating on diesel engine performance and emissions.
• To compare the effectiveness of coated versus uncoated pistons under various load conditions.
• To analyze combustion characteristics with ceramic-coated pistons using diesel and biodiesel fuels.

Main Methods:

• Plasma spray coating was used to apply yttria-stabilized zirconia to Kirloskar single-cylinder diesel engine pistons.
• Engine performance (efficiency, fuel consumption) and emissions (HC, CO, NOx) were measured.
• Combustion parameters, including heat release rate and pressure, were analyzed.

Main Results:

• Coated pistons demonstrated significantly increased brake thermal efficiency and decreased specific fuel consumption across all tested loads.
• Emissions analysis showed a reduction in hydrocarbon and carbon monoxide pollutants with the coated piston.
• An increase in nitrogen oxides was observed, which can be managed through optimized injection timing and pressure.

Conclusions:

• Yttria-stabilized zirconia ceramic coating enhances diesel engine efficiency and reduces key emissions.
• The coating effectively insulates components, leading to higher combustion temperatures and improved heat release.
• Further optimization of fuel injection parameters is recommended to mitigate NOx increases, maximizing the benefits of thermal barrier coatings.