Development of Thermal Corrosion and Wear Resistant Plasma Sprayed Coatings for Internal Combustion Engine

Abstract

In order to improve the thermal and combustion efficiencies of internal combustion newlineengines, one should use Thermal Barrier Coatings (TBCs). The existing literature shows that newlineat present TBCs are deposited on combustion chamber components such as piston crowns, newlinepiston rings, cylinder cover, valves and cylinder liner. In internal combustion engines, cylinder newlineliner is one of the important components which undergoes severe wear and tear due to the newlinereciprocating motion of the piston. Simultaneously, it is exposed to thermal stresses developed newlineby the hot products of combustion. The TBC which is used as a cylinder liner should minimise newlinethe wear and tear, heat loses from the cylinder. A lot of works have been carried out on the newlineimplementation of TBC as an engine cylinder liner. However, the extended application of TBC newlineto cylinder liner has not been explored practically. The difficulty faced by the researchers in newlineimplementing TBC as engine cylinder liner is thermal mismatch which mainly occurs due to newlinethe difference in thermal expansion coefficients between bond coat and cylinder material. This newlinethermal mismatch leads to improper adhesion between coating and substrate. TBC liner must newlinealso withstand wear and tear. It is required to overcome these problems to implement TBC as newlinean engine cylinder liner. It is in this context an attempt has been made to develop a TBC which newlineis also wear resistant coating to be used in IC diesel engine as a liner. newlineIn this investigation, two substrate materials Al-6061 and cast iron were selected. On newlineAl-6061 substrate two bond coats were applied. The first bond coat was Metco 446 metal newlinepowder which has a composition of Al 25Fe7Cr5Ni; second bond coat is Metco 410 NS cermet newlinepowder which has a composition of Al2O3 30(Ni20Al). For cast iron substrate, the first bond newlinewas Metco 452 which has a composition of Fe 38Ni10Al and the second bond coat was Metco newline410 NS. For both the substrates, the top coat was the mixture of alumina and yttria stabilised newlinezirconia in 50:50 proportion by weig