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ABSTRACT

This project is aimed at improving the performance of diesel engine. Diesel engines burn

fuel oils, which require less refining and are cheaper than higher-grade fuels such as petrol.

During the combustion process, the stored chemical energy in the fuel is converted to the

thermal, or heat, energy.

During combustion, the top surface of the piston faces the maximum temperature. Due to

conduction, this heat is transferred throughout the piston. As heat is generated continuously in

the piston surface, conduction takes place rapidly allowing more heat to be conducted to the

piston. Due to this, some amount of heat which is to be combusted is lost to the piston. Also the

piston tends to get expanded due to the high temperature of heat which is transferred to piston.

In this study, a coating is done on the top surface of the piston to reduce the heat which is

being transferred throughout the piston. Functionally graded materials which have a low thermal

conductivity is been applied as coating to the top surface of the piston. Thermal analysis is done

on both the uncoated and coated piston and the stress results are compared. The thermal stresses

obtained are compared with the numerically obtained values. The thermal stress of coated piston

is found less than the uncoated piston which results in reduced heat transfer in the piston.
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ACKNOWLEDGEMENT

First and foremost I would like to thank the Lord Almighty for His presence and immense

blessings throughout the project work.

It’s a matter of pride and privilege for me to express my deep gratitude to the management of

HITS for providing me the necessary facilities and support.

I am highly elated in expressing my sincere and abundant respect to the Vice Chancellor

Dr.S.Ramachandran for giving me this opportunity to bring out and implement my ideas in this

project.

I wish to express my heartfelt gratitude to Dr.T.S.Ravikumar Ph.D, Head of the Department of

Mechanical Engineering for much of his valuable support encouragement in carrying out this

work.

I would like to thank my internal guide Mr .Dr.P.Vijayabalan M.E., Ph.D. for continually

guiding and actively participating in my project, giving valuable suggestions to complete the

project work.

I would like to thank all the technical and teaching staff of the Mechanical Engineering

Department, who extended directly or indirectly all support.

Last, but not the least, I am deeply indebted to my parents who have been the greatest support

while I worked day and night for the project to make it a success
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TABLE OF CONTENTS

CHAPTER TITLE PAGE


NO. NO.
Abstract i
List Of Tables v
List Of Figures vi
List Of Abbreviations vii
1 INTRODUCTION
1.1. Thermal Barrier Coating 1

2 LITERATURE REVIEW 4

3 PISTON
3.1. Internal Combustion Engines 6

3.2. Applications 6

3.2.1. Air Compressors 8

3.2.2. Gas Generators 8

4 COATING
4.1. Nanocoating 9

4.1.1. Electrical Beam Physical Vapor Deposition 9

4.1.2. Material Evaporation Method 10

4.2. The Substrate 11

4.3. Functionally Graded Coating 11

4.4. Advantages & Applications Of Zirconia Thermal 14

Barriers
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5 FINITE ELEMENT ANALYSIS


5.1. Steps Involved In Finite Element Analysis 16

5.2. Ansys Analysis 16

5.3. Ansys Evaluation 17

5.4. Structural Analysis 18

5.4.1. Types Of Solution Methods 19

5.4.2. Structural Static Analysis 19

5.4.3. Apply Loads To The Model 20

5.4.4. Meshing 20

5.5. Thermal Analysis 23

5.5.1. Convection 23

5.6. Types Of Thermal Analysis 25

5.6.1. Steady-State Thermal Analysis 26

5.6.2. Transient Thermal Analysis 26

5.6.3. Coupled-Field Analysis 27

5.7. Coated Piston 28

5.8. Uncoated Piston 29

6 PLASMA SPRAY COATING


6.1 Zirconia Dioxide 31

6.2 Thermal Spray Technique 31

6.3 Overview Of Plasma Spray Process 32

7 TESTING OF SPECIMEN AND RESULT


7.1 Aluminium Without Zirconia 34

7.2 Aluminium With Zirconia Coated 36

7.3 Hardness Test 37

7.4 Saltspray Test 38

8 CONCLUSION 39

REFERENCES
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LIST OF TABLES

TABLE NO TABLE NAME PAGE NO

5.1 Element Used In Structural Analysis 16

5.2 Define Load 16

5.3 Material Properties Of Aluminium 22

5.4 Material Properties Of Zirconia 23

7.1 Hardness Comparison 37


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LIST OF FIGURES

FIGURE NO FIGURE NAME PAGE NO

3.1 Component Of Diesel Engine 6

3.2 Piston Assembly 8

4.1 Electron Beam Physical Vapour Deposition 12

4.2 Top Groove Hard Anodize 13

4.3 Skirt Coating 14

4.4 Thermal Barrier Crown 14

4.5 Koolkote 14

5.1 Coated Piston 28

5.2 Uncoated Piston 29

5.3 Comparison Between Coated And Uncoated Piston 30

6.1 Thermal Spray Process 31

6.2 Plasma Spray Coating Process 32

7.1 Aluminium Without Zirconia 33

7.2 Aluminium With Zirconia 35


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LIST OF ABBREVIATIONS

S.NO ABBREVATION DESCRIPTION


1 CVD Chemical Vapour Deposition

2 FEA Finite Element Analysis

3 LHR Low Heat-Rejection

4 MEMS Micro-Electromechanical Systems

5 PECVD Plasma-Enhanced Chemical Vapour


Deposition
6 PVD Physical Vapour Deposition

7 TBC Thermal Barrier Coating

8 TEC Thermal Expansion Coefficient

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