Thermo-mechanical analysis of a coated cylinder head

Document Type: English

Author

Sama technical and vocational training college, Islamic Azad University, Varamin Branch, Varamin, Iran

Abstract

This paper presents finite element analysis (FEA) of a coated and uncoated cylinder heads of a diesel engine to examine the distribution of temperature and stress. A thermal barrier coating system was applied on the combustion chamber of the cylinder heads, consists of two-layer systems: a ceramic top coat (TC), made of yttria stabilized zirconia (YSZ), ZrO2-8%Y2O3 and also a metallic bond coat (BC), made of Ni-Cr-Al-Y. The coating system in this research comprises 300 μm zirconium oxide TC and 150 μm BC. The three-dimensional model of the cylinder heads was simulated in abaqus software and a two-layer viscoplasticity model was utilized to investigate the elastic, plastic and viscous behavior of the cylinder heads. The elastic and plastic properties of BC and TC layers were considered and the effect of thermal barrier coatings on distribution of temperature and stress was investigated. The aim of this study is to compare the distribution of temperature and stress in the coated and uncoated cylinder heads under thermo-mechanical loads. The results of FEA showed that the thermal barrier coating system reduces the temperature about 53°C because of its lower thermal conductivity. As a result, the cylinder heads tolerates lower temperature and fatigue life will increase. The results of thermo-mechanical analysis indicated that the stress in the coated cylinder heads decreased approximately 24 MPa for the sake of depletion of temperature gradient which can lead to higher fatigue lifetime.

Keywords

References

[1]      M. Metzeger, M. Leidenfrost, E. Werner, H. Riedel, and T. Seifert, “Lifetime Prediction of EN-GJV 450 Cast Iron Cylinder Heads under Combined Thermo-mechanical and High Fatigue Loading,” SAE International Paper No.2014-01-9047, 2014.

[2]      F. Zahedi, and M. Azadi, “Low cycle fatigue life analysis of magnesium alloy diesel engine cylinder head,” 20th Annual International Conference on Mechanical Engineering, Shiraz , 2012.

[3]      M. Azadi, G. Winter, G.H Farrahi, and W. Eichlseder, “ Design of cylinder head and block in international combustion engines based on fatigue strength of materials,” 8th International Conference on Internal Combustion Engines and Oil, Tehran, 2012.

[4]      G.H. Farrahi, M. Ghodrati,  M. Azadi, and  M. Rezvani Rad, “ Stress-strain time-dependent behavior of A356.0 aluminum alloy subject to cyclic thermal and mechanical lading,” Journal of Mech Time-Depend Mater, vol. 18,  pp. 475-491, 2014..

[5]      M.H. Shoja'efard, M.R. Ghaffarpour, A.R. Nourpour, and S. Alizadenia, “Thermo-mechanical Analysis of an Engine Cylinder Head,” Journal of  Automotive Engineering, vol. 220, pp. 627-636, 2006..

[6]      M. Quazi, and S. Parashar, “Effect of Thermal Bearing Coating on Performance and Emission of Off Road Vehicle,” SAE International, Paper No. 2015-26-0065, 2015.

[7]      S. Rupangudi, C. Ramesh, and K.V. Veerabhadhrappa, “ Study of Effect of Coating of Piston on the Performance of a Diesel Engine,” SAE International, Paper No. 2014-01-1021, 2014.

[8]      P. Ramu, and C.G. Saravanan,  “Effect of ZrO2-Al2O3 and SiC coating on diesel engineto study the combustion and emission characteristics,” SAE International, Paper No.2009-01-1435, 2009.

[9]      I. Taymaz, “The effect of thermal barrier coatings on diesel engine performance,” Journal of Surface and Coatings Technology, vol. 201, pp. 5249-5252, 2007.

[10]  M. Rezvani rad,  G.H. Farrahi, M. Azadi, and M. Ghodrati, “ Stress analysis of thermal barrier coating system subjected to out-of-phase thermo-mechanical loadings considering roughness and porosity effect,” Journal of surface & coating technology, vol. 262, pp. 77-86, 2015.

[11]  M. Azadi,  M. Balo, G.H. Farrahi, and S.M. Mirsalim, “A review of thermal barrier effects on diesel engine performance and components lifetime, International Journal of Automotive Engineering,” vol. 3,  pp. 305-317, 2013.

[12]  A. Moridi, M. Azadi, and G.H. Farrahi, “Thermo-mechanical stress analysis of thermal barrier coating system considering thickness and roughness effects,” Journal of surface and coating, vol. 243, 2014, pp. 91-99.

[13]  M. Bialas, “Finite element analysis of stress distribution in thermal barrier coating, Journal of surface and coating,” vol. 202, pp. 6002-6010, 2008.

[14]  K. Slámečka, L. Čelko, P. Skalka,  J. Pokluda,  K. Němec,  M. Juliš, L. Klakurková, and  J. Švejcar, “Bending fatigue failure of atmospheric-plasma-sprayed CoNiCrAlY+ YSZ thermal barrier coatings,”International Journal of Fatigue, vol. 70, pp. 186-195, 2015.

[15]  R. Kamo, and W. Bryzik, “Adiabatic turbo-compound engine performance prediction,” SAE International, Paper No.780068, 1978.

[16]  R. Kamo, and W. Bryzik, “Ceramics in heat engines,” SAE International, Paper No.790645, 1979.

[17]  R. Kamo, and W. Bryzik, “Cummins-TRADOCOM adiabatic turbo-compounded engine program,” SAE International, Paper No.810070,1981.

[18]  R. Kamo, and W. Bryzik, “Cummins/TACOM advanced adiabatic engine,” SAE International Paper No. 840428, 1984.

[19]  R.P. Sekar, and R. Kamo, 1984, “Advanced adiabatic diesel engine for passenger cars,” SAE International, Paper No. 840434, 1984.

[20]  R. Kamo, M.E. Woods,  and W. Bryzik,  Thin thermal barrier coating for engines, United States Patent, Patent No. US4852542, 1989.

[21]  M.F. Winkler, and D.W. Parker, “The role of diesel ceramic coatings in reducing automotive emissions and improving combustion efficiency,” SAE International Paper No. 930158, 1993.

[22]  M.F. Winkler, D.W. Parker, and J.A. Bonar,1992, “Thermal barrier coatings for diesel engines: ten years of experience,” SAE International, Paper No. 922438, 1992.

[23]  M. Ranjbar-Far, J. Absi, G. Mariaux, and F. Dubois, “ Simulation of the effect of material properties and interface roughness on the stress distribution in thermal barrier coatings using finite element method,” Journal of Materials and Design, vol. 31, pp. 772-781, 2010.

[24]  L. Wang, Y. Wang, W.Q. Zhang, X.G. Sun, J.Q. He, Z.Y. Pan and , C.H. Wang, “Finite element simulation of stress distribution and development in 8YSZ and double-ceramic-layer La2Zr2O7/8YSZ thermal barrier coatings during thermal shock,” Journal of Applied Surface Science, vol. 258, pp. 354-355, 2012.

[25]  M. Cerit, 2011, “Thermo mechanical analysis of a partially ceramic coated piston used in an SI engine, Journal of  Surface and Coatings Technology,” vol. 205,  pp. 3499-3505, 2011.

[26]  M. Durat, M. Kapsiz, E. Nart, F. Ficici, and  A. Parlak, “The effects of coating materials in spark ignition engine design, Journal of material and design,” vol.  36, 2012, pp. 540-545.

[27]  M. Marr, J. Wallace, S. Memme, S. Chandra, L. Pershin, and J. Mostaghimi, “An Investigation of Metal and Ceramic Thermal Barrier Coatings in a Spark-Ignition Engine,” SAE International, Paper No.2010-01-2090, 2010.

[28]  D. Saad,P.Saad, L. Kamo, M. Mekari, W. Bryzik, and J. Tasdemir, “Thermal barrier coatings for high output turbocharged diesel engine,” SAE International, Paper No. 2007-01-1442, 2007.

[29]  E. Buyukkaya, and M. Cerit,  “Thermal analysis of a ceramic coating diesel engine piston using 3-D finite element method, ” Journal of surface & coating technology, vol. 202, pp. 398-402, 2007.

[30]  S. Du, X. Hu, Y. Feng, and J.Cheng, 2008, “Thermal Analysis of Functional Gradient Materials as Thermal Barrier Coating of Piston,” SAE International, Paper No. 2008-01-2754, 2008.

[31]  T. Hejwowski, “Comparative study of thermal barrier coating for internal combustion engine,” Journal of vacuum, vol. 85, pp. 610-612, 2010.

[32]  G. Sivakumar, and S. Kumar, “Investigation on effect of yttria stabilized zirconia coated piston crown on performance and emission characteristic of diesel engine,” Alexandria engineering journal, doi.org/10.1016/j.aej.2014.08.003, 2014.

[33]  M. Ekström,  A. Thibblin, A. Tjernberg, C. Blomqvist, and S.  Jonsson, “Evaluation of internal thermal barrier coatings for exhaust manifolds,” Journal of surface & coatingtechnology, vol. 272, pp. 198-212, 2015.

[34]  M. Rezvani rad, M., Azadi, G.H. Farrahi, “Thermal barrier coating effect on stress distribution of a diesel engine cylinder head,” 7th Iranian Student Conference on Mechanical Engineering, School of Mechanical Engineering, University of Tehran, Tehran, Iran, 2013.

[35]  E. Buyukkaya, “Thermal analysis of functionally graded coating AlSi alloy and steel pistons, Journal of surface & coating technology,” vol. 202, pp. 3856-3865, 2008.

[36]  H. Ashouri, “Thermo-mechanical analysis of diesel engines cylinder heads using a two-layer viscoelasticity model with considering viscosity effects, International Journal of Automotive Engineering,” vol. 5, pp. 1026-1038, 2015.

[37]  J.J. Thomas, L. Vergner,  A. Bignonnet, and E. Charkaluk, “Thermo-mechanical design in the automotive industry,” Journal of  Fatigue and Fracture of  Engineering Material and Structure, vol. 27, pp. 887-895, 2004.

[38]  J. Kichenin, K. Dang van, and K. Boytard, 1996, “Finite-element simulation of a new two-dissipative mechanisms model for bulk medium-density polyethylene,” Journal of material science, vol. 32, pp. 1653-1661, 1996.

[39]  A. Deshpande, S.B. Leen, and  T.H. Hyde, “Experimental and numerical characterization of the cyclic thermo-mechanical behavior of a high temperature forming tool alloy,” ASME Journal of Manufacturing Science and Engineering, vol. 132, pp. 1-12, 2010.

[40]  J. Lemaitre, and J. Chaboche, Mechanics of Solid Materials, Cambridge University Press, Cambridge, 1990.

[41]  J.L. Chaboche, “Time-independent constitutive theories for cyclic plasticity,” International Journal of Plasticity, vol.2, no. 2, pp. 149–188, 1986.

[42]  J.L. Chaboche, “A review of some plasticity and viscoplasticity constitutive theories, International Journal of Plasticity,” vol. 24, pp. 1642–1693, 2008.

[43]  M. Angeloni,  Fatigue life evaluation of A356 aluminum alloy used for engine cylinder head, Ph.D. Thesis, University of Sau Palu, Brazil,  2011.

[44]  G.Q. Sun, and D.G Shang, “Prediction Of  Fatigue Lifetime Under Multiaxial Cyclic Loading Using Finite Element Analysis,” Journal of  Material and Design, vol. 31, pp. 126-133, 2010.

[45]  S. Trampert, T. Gocmez, and S. Pisinger, 2008, “Thermo-mechanical fatigue life prediction of cylinder head in combustion engines,” Journal of Engineering for Gas Turbines and Power, vol. 130, pp.1-10, 2008.

[46]  ABAQUS/CAE(v6.10-1), User’ s Manual , 2010.

[47]  H.R. Chamani,  I. Sattarifar, and M. Mohammadi Aghdam, “ Study of effect combustion gases and cooling thermal boundary conditions on temperature distribution of a heavy diesel engine cylinder head,” Journal of engine research, vol. 17, pp. 71-81, 2009.

[48]  L. Wang, Y. Wang, W.Q. Zhang, X.G. Sun, J.Q. He, Z.Y. Pan and , C.H. Wang, 2012, “A novel structure design towards extremely low thermal conductivity for thermal barrier coatings –Experimental and mathematical study,” Materials and design, vol.  35, pp. 505-517, 2012.

[49]  R. M. Mahamood, E. T .Akinlabi Member, I. M. Shukla, and S. Pityana, “ Functionally Graded Material: An Overview, Proceedings of the World Congress on Engineering,” London, U.K.,2012.

Journal of Simulation and Analysis of Novel Technologies in Mechanical Engineering

Volume 10, Issue 2
Spring 2017
Pages 35-48

Files

Share

How to cite

Statistics