The document describes a project to analyze the effects of applying thermal barrier coatings to diesel locomotive engines. The objectives are to increase power output and efficiency while reducing fuel consumption, emissions, and wear on engine components. The project involves studying engine components, applying thermal barrier coatings, analyzing coatings using simulation software, and reporting on design considerations and results. Thermal barrier coatings aim to insulate components and allow higher operating temperatures to improve performance and lifespan.

2. Project Title :
“Design analysis of Diesel Locomotive engine with & without thermal barrier coating”

3. Objective :
To increase the power output/Horse power
(HP) & efficiency of diesel locomotive
engine.
To reduce fuel & lube oil consumption and
to increase the thermal efficiency of the
engine.
To reduce the NOx, particulate, CO & black
smoke emissions.

4. Detailed study &
observation of
the locomotive
engines.
Design &
modification of
the various
elements in
order to increase
the Horse Power
(HP) & to
increase fuel
efficiency.
Analysing using
modelling
software’s like
Solidworks,
abaqus & ANSYS.
Final Project
report on the
design
considerations,
modifications &
analysis done.
Project Flow Process :

5. Literature study & understanding of the diesel
engine & its components.
Thermal barrier coating of various engine
components to increase their duty cycle, increase
in better fuel combustion, reduce fuel &lube
consumption.Detailed analysis of thermal barrier coating on
various engine components & careful observation of
its effects, so as to make the necessary modifications
& design considerations
Project Procedure :

6. Introduction :
 Thermal barrier coatings consist of four layers: the metal substrate, metallic bond coat,
thermally grown oxide, and ceramic topcoat.
 The ceramic topcoat is typically composed of yttria-stabilized zirconia (YSZ) which is
desirable for having very low conductivity while remaining stable at nominal operating
temperatures.
 The oxide that is commonly used is Zirconia oxide (ZrO2) and Yttrium oxide (Y2O3). The
metallic bond coat is an oxidation/hot corrosion resistant layer. The bond coat is
empherically represented as MCrAlY alloy where
M - Metals like Ni, Co or Fe.
Y - Reactive metals like Yttrium.
CrAl - base metal.
 This ceramic layer creates the largest thermal gradient of the TBC and keeps the lower
layers at a lower temperature than the surface.

7. Thermal barrier coating consisting of metallic bond coat on
the substrate and ceramic top coat on the bond coat.

8. Project Challenges :
 To search a proper bond coatings and top coat materials based on composition
of substrates.
 Selection of proper coatings techniques.
 Preparation of plasma sprayed coated samples for various tests.
 To check the microstructure and Topology of coating.
 To check the surface texture parameter of coating.
 To determine the bond strength of coating.
 To determine micro hardness of coating.
 To determine abrasive wear of coating .
 To determine erosion wear of coating.
 To establish the suitability of coatings for its application in internal combustion
Engine as a linear.

10. Literature Survey :
 Thermal barrier coatings are highly advanced material systems usually applied to
metallic surfaces, operating at elevated temperatures, as a form of Exhaust Heat
Management.
 These coatings serve to insulate components from large and prolonged heat loads by
utilizing thermally insulating materials which can sustain an appreciable temperature
difference between the load bearing alloys and the coating surface.
 In doing so, these coatings can allow for higher operating temperatures while
limiting the thermal exposure of structural components like piston, connecting rods
etc in case of diesel engines & also extending part life by reducing oxidation and
thermal fatigue.
 In conjunction with active film cooling, TBCs permit working fluid temperatures
higher than the melting point of the metal.
 Exhaust gas temperature changing between 400-600 0C for conventional diesel
engines while it is between 700-900 0C for thermal barrier coated engine

11. Thermal Efficiency for Baseline and Ceramic Coated Engines

12. Ceramic Process-
Reactive
Infiltration
5µm
ab
Fig .NiAl Al2O3 composite.
•Dark phase is ceramic.
Alternate Ceramic Process-
Reactive Infiltration
Established Processing Scheme
SiO2 shaped precursor is
immersed in liquid Al at 1100
degree C.
4Al+3SiO2 --> 2Al2O3+3Si
As 2 moles of Al2O3 are smaller
than
3 moles of SiO2, porous alumina
created and infiltrated!
Enhancements in this program
Use high melting metal or intermetallic to
fill pores in ceramic instead of aluminum.
Add continuous ceramic fibers as well.

13. DESIGN MATERIAL REQUIREMENT FOR TBC
•Some of the innumerable design options with regard to TBC are given below.
Fuel Flexibility
Corrosion resistance
Availability and Reliability
Corrosion / Erosion resistance
Lower metal temperature
Lower transient thermal stress
Efficiency
Reduce coolant flow
 Increase the turbine inlet temperature
Capital cost
Easily cast super alloy
Simplified cooling

14. BSFC as a Function of Speed for Baseline and Ceramic Coated Engines

15. PROPOSED APPROACH
Begin with models of Begin with models of Zirconia Oxideco(Z2O3)atings with Yttrium Oxide( Y2O3)coats and
superalloy substrates which incorporate phase evolution, thermally growing oxide, and damage evolution.
Compare simulations of isothermal and thermocylic loading to existing experimental data.
Simulations of top coat materials with varying degrees of compliance and accounting for sintering and CMAS
depositions.
Investigate alternative top coat materials and structures through materials design simulations.
To design an optimal set of residual stresses and crack compliances for improved coating performance and life.
Coatings with Zirconia Oxide(Z2O3)and superalloy substrates which incorporate phase evolution, thermally
growing oxide, and damage evolution.
Compare simulations of isothermal and thermocylic loading to existing experimental data.
Simulations of top coat materials with varying degrees of compliance and accounting for sintering and CMAS
depositions.
Investigate alternative top coat materials and structures through materials design simulations.
To design an optimal set of residual stresses and crack compliances for improved coating performance and life.

16. STUDY OF TBC IN PROGRESS
Some of the work related to Thermal Barrier Coating undergoing are
i. A study of solid-state reactions between the ceramic layer, the bond coat metal
oxides, the bond coat and substrate.
ii. A study to determine the kinetics of phase transformation in the ZrO2-12Y2O3
system and the effect of such transformations on mechanical properties.
Detailed analysis of coating stresses and controlled process, plasma spray
technology has significantly improved the reliability of TBC turbines, diesel engines
and other heat engines.
Processing improvement in the control and development of TBC are required,
further study on, the mechanisms controlling coating adherence and degradation in
clean and dirty environments.
The effects of coating composition and structure on coating properties and correlation
of models of engine tests are necessary to obtain thermal barrier coating that have
even better tolerance to high temperature and thermo mechanical stresses.

17. ADVANTAGES OF THERMAL BARRIER COATINGS FOR
DIESEL ENGINES
 Using lower-quality fuels within a wider distillation range
 Reduce Specific fuel consumption
 Multi-Fuel capability
 Faster vapourization & better mixing of fuel
 Decrease knocking & noise caused during combustion
 Ignition delay of fuel is reduced
 Increased thermal & effective efficiency
 Improvement occour at emissions
,

18. OTHER ADVATAGES OF TBC IN DIESEL ENGINES
Thermal Barrier Coatings developed primarily for turbine
applications can also be used in diesel engines benefits derived from
using this technology includes
An improvement in the diesel engine fuel economy.
Increase in engine power density.
40% heat reduction in in-cylinder heat rejection.
Reduction in the ring groove temperatures.
Reduction in the metal piston temperatures
Reduction in the lubricant temperatures

19. DISADVANTAGES OF TBC
The main disadvantage is ceramic bond coat interface region
which was determined to be the weakest link in the ZrO2-12Y2O3
/NiCrAlYsystem.
Adhesive plus cohesive failure of the ceramic layer in this region
occurred when the coating was subjected to a normal tensile load at
room temperature as well as when applied on bars subjected to axial
tension or compression at elevated temperature.

20. APLLICATIONS OF TBC
Thermal barrier coatings can also be applied on :furnace
components
heat-treating equipments
chemical processing equipments
heat exchangers rocket motor nozzles
exhaust manifolds
jet engine parts and nuclear power plant components.
It has also been applied to uncoated blades used to
drive the high-pressure hydrogen turbo pump of the
Space Shuttle Main Engine. Here the coating is applied
to provide thermal lag.

21. Increase in Power to weight ratio & overall
performance of the locomotive engine.
Increased fuel efficiency thereby control in diesel fuel
expenditure.
Control & reduction in diesel emission like NOx which
is a major concern.
Extended duty life cycle of engine components due to
thermal barrier coating.
Reduction in consumption of lube oil & coolants due
to thermal barrier coating.
Future Scope :

22.  With insulating combustion chamber components, it is available to keep combustion
temperatures high.
 Due to high combustion temperatures thermal efficiency can be increased, exhaust
emissions can be improved and fuel consumption can be decreased on diesel engines.
 Ceramic materials which have low thermal conductivity and high thermal expansion
coefficient are used for making combustion chamber components thermal insulated.
 For a successful coating thermal coating, ceramic material has a high melting point,
high oxygen resistance, high thermal expansion co efficient, high corrosion resistance,
high strain tolerance, low thermal conductivity and phase stability.
CONCLUSION :