Thermal Barrier Coatings (TBCs), routinely prepared from Ceramic based compositions (typically
8%Y2O3-ZrO2or 8YSZ) are being engineered to protect the metallic components from degradation in
applications like gas turbines, jet and automotive engines. With a goal of finding improved TBC materials
a wide variety of ceramics are being researched worldwide. Before physically preparing the TBCs of
uncommon compositions in the laboratory, their suitability to perform can be predicted. Limited
accessibility to detailed and realistic information on the influence of newer compositions (other than 8YSZ)
on TBCs warrants methods to obtain this information.
In this paper, 8YSZ TBCs coated onto aluminium substratesare studied for thermal fatigue, thermal barrier
and materials characteristics to determine the reliability of the coating configuration to withstand the
harshness of test conditions under the framework of experiments. Thereafter, the results have been used to
corroboratethe developed simulation model. Results obtained via thermal tests confirm the suitability of the
model and we can predict the thermal barrier effects of TBCs when prepared from materials other than
YSZ.
LAB SCALE PREPARATION AND EVALUATION OF YTTRIA STABILIZED ZIRCONIA THERMAL BA...ijmech
Ceramic based coatings are routinely being engineered to protect metallic components from high
temperature environments in applications like gas turbines and jet engines. However, although a wellresearched
technology, detailed and realistic information on the effects of thermal barrier coatings (TBCs)
in improving the performance of commercial diesel engines is either classified or inconsistent. Additional
information by means of lab scale and analytical evaluation of TBCs prepared from 8%Y2O3-ZrO2 plasma
sprayable powders (prepared in the laboratory by using organic binders), coated onto aluminium
substrates, corroborated by simulation model is one part of this paper. The findings are supplemented by
studying the influence of the TBCs on aluminium pistons in a single cylinder nine horsepower class diesel
engine, thereby carrying out realistic performance of the engine involving parameters such as Power
(Brake, Indicated and Frictional), thermal efficiency, fuel consumption, effects of ceramic insulation on
emission and exhaust temperature and peak cylinder pressure, as the concluding part of the studies.
A Review on Investigation of Tribological Behavior of Nanocoating for Piston ...IJLT EMAS
Nanocoating can help to improve performance and life
of automotive engine by reducing the wear between the engine
components. In this research have selected the proper material
for top piston ring and same material are to be selected for
preparation of pin for tribometer testing and material of cylinder
liner tested and fabricated the same material of tribometer disc.
Nanocoating by electroplated Chromium coating and Chromium
nitride using DLC method by PVD coating was done on
specimen pin and piston ring and this material which was used
tribometer testing.
Depleting fossil fuel resources, economic
competitiveness and environmental concerns has compelled to
explore newer avenues to improve efficiency of automotive
engines. Various techniques have been adapted to achieve this
goal.
Thermal Barrier Coating For Gas Turbine EnginesNelsonkandulna
This presentation describes the thermal barrier coating process, its anatomy, types, material selection, failure, and characterization. Thermal barrier coatings (TBCs) were introduced to protect the external surface of gas turbine engine components from thermal resistance and thereby decrease the temperature of the metal surfaces. Yttria stabilized zirconia (YSZ) is one of the most popular and widely used TBC materials as it provides the best performance in high-temperature zones such as diesel engines and gas turbines. The columnar microstructure of YSZ coating provides excellent strain tolerance and adhesion to the coating. Gas turbines are used to power aircraft, trains, ships, electrical generators, pumps, gas compressors, and tanks.
Structural and Thermal Analysis of Metal - Ceramic Disk BrakeIJSRD
Disk brakes are using from so many years in automotive and still researches are going on in this field for decreasing the temperature effect so that by this we can operate easily. Many new materials are introduced for the disk brake rotor to withstand high temperature produced during braking action. Apart from the high temperature property, the disc rotor materials must also have high thermal conductivity property, as this property decides the amount of heat dissipation to the air stream from the disk rotor. A brake material with good temperature and high thermal conductivity property gives maximum efficiency by overcoming the problem of thermo-mechanical instability [TEI] in the rotor which is more common in low thermal conductivity brake rotor material. In the present work, a Grey cast iron material and metal-ceramic has been chosen for the disk brake rotor. Number of methods before already introduced to know the history of the different materials related to disk brakes, analysis will be done in 2d and 3d in analytical and numerical methods. With different types of assumptions these numerical methods ranges from finite differences to finite elements. To conclude the temperature history for the Grey cast iron material, and metal-ceramic, a numerical simulation technique called finite element method is used. Transient analysis is carried out in ANSYS to predict temperature distribution as a function of time in the disk brake rotor. The results from the transient analysis are compared. As the brake rotor can be treated as the coupled field problem, it is mandatory to do structural analysis after performing thermal analysis in ANSYS to study the stability and rigidity behavior of the rotor material. The results from the transient analysis are given as the input to the structural analysis in order to conclude the stress distribution and displacement in disk brake rotor under thermal loading. The stability behavior of different brake rotor material is compared to facilitate the conceptual design of the disk brake system.
LAB SCALE PREPARATION AND EVALUATION OF YTTRIA STABILIZED ZIRCONIA THERMAL BA...ijmech
Ceramic based coatings are routinely being engineered to protect metallic components from high
temperature environments in applications like gas turbines and jet engines. However, although a wellresearched
technology, detailed and realistic information on the effects of thermal barrier coatings (TBCs)
in improving the performance of commercial diesel engines is either classified or inconsistent. Additional
information by means of lab scale and analytical evaluation of TBCs prepared from 8%Y2O3-ZrO2 plasma
sprayable powders (prepared in the laboratory by using organic binders), coated onto aluminium
substrates, corroborated by simulation model is one part of this paper. The findings are supplemented by
studying the influence of the TBCs on aluminium pistons in a single cylinder nine horsepower class diesel
engine, thereby carrying out realistic performance of the engine involving parameters such as Power
(Brake, Indicated and Frictional), thermal efficiency, fuel consumption, effects of ceramic insulation on
emission and exhaust temperature and peak cylinder pressure, as the concluding part of the studies.
A Review on Investigation of Tribological Behavior of Nanocoating for Piston ...IJLT EMAS
Nanocoating can help to improve performance and life
of automotive engine by reducing the wear between the engine
components. In this research have selected the proper material
for top piston ring and same material are to be selected for
preparation of pin for tribometer testing and material of cylinder
liner tested and fabricated the same material of tribometer disc.
Nanocoating by electroplated Chromium coating and Chromium
nitride using DLC method by PVD coating was done on
specimen pin and piston ring and this material which was used
tribometer testing.
Depleting fossil fuel resources, economic
competitiveness and environmental concerns has compelled to
explore newer avenues to improve efficiency of automotive
engines. Various techniques have been adapted to achieve this
goal.
Thermal Barrier Coating For Gas Turbine EnginesNelsonkandulna
This presentation describes the thermal barrier coating process, its anatomy, types, material selection, failure, and characterization. Thermal barrier coatings (TBCs) were introduced to protect the external surface of gas turbine engine components from thermal resistance and thereby decrease the temperature of the metal surfaces. Yttria stabilized zirconia (YSZ) is one of the most popular and widely used TBC materials as it provides the best performance in high-temperature zones such as diesel engines and gas turbines. The columnar microstructure of YSZ coating provides excellent strain tolerance and adhesion to the coating. Gas turbines are used to power aircraft, trains, ships, electrical generators, pumps, gas compressors, and tanks.
Structural and Thermal Analysis of Metal - Ceramic Disk BrakeIJSRD
Disk brakes are using from so many years in automotive and still researches are going on in this field for decreasing the temperature effect so that by this we can operate easily. Many new materials are introduced for the disk brake rotor to withstand high temperature produced during braking action. Apart from the high temperature property, the disc rotor materials must also have high thermal conductivity property, as this property decides the amount of heat dissipation to the air stream from the disk rotor. A brake material with good temperature and high thermal conductivity property gives maximum efficiency by overcoming the problem of thermo-mechanical instability [TEI] in the rotor which is more common in low thermal conductivity brake rotor material. In the present work, a Grey cast iron material and metal-ceramic has been chosen for the disk brake rotor. Number of methods before already introduced to know the history of the different materials related to disk brakes, analysis will be done in 2d and 3d in analytical and numerical methods. With different types of assumptions these numerical methods ranges from finite differences to finite elements. To conclude the temperature history for the Grey cast iron material, and metal-ceramic, a numerical simulation technique called finite element method is used. Transient analysis is carried out in ANSYS to predict temperature distribution as a function of time in the disk brake rotor. The results from the transient analysis are compared. As the brake rotor can be treated as the coupled field problem, it is mandatory to do structural analysis after performing thermal analysis in ANSYS to study the stability and rigidity behavior of the rotor material. The results from the transient analysis are given as the input to the structural analysis in order to conclude the stress distribution and displacement in disk brake rotor under thermal loading. The stability behavior of different brake rotor material is compared to facilitate the conceptual design of the disk brake system.
Since so many years a problem occurs in KSB Pump Va mbori for casting process i.e. cracks occurs in the castings & it is repeated one. Therefore the compan y has given opportunity to me to solve this problem . In case of steel casting there are mainly cracks & also blo w holes induced due to the casting procedure. There are many factors for the casting defects .The factor is unev en material feeding in casting & also due to the mo uld material & also the core material. These cracks finally brea k directly the component of the casting i.e. in cas e of pump the casting component is like Impeller,Volute casing & casing cover. At the time of feeding of steel material in to the casting the material is in liquid us form i.e. it i s hot material & this material is feeding into casting at the time o f feeding it develop different region of heat. At o ne side the temp is high &at other side the temp is low this also pr oduce cracks. To simulate that casting we use the M AGMA SOFTWARE for simulation & validate it using NDT.
Contact Pressure Validation of Steam Turbine Casing for Static Loading ConditionIJMER
International Journal of Modern Engineering Research (IJMER) is Peer reviewed, online Journal. It serves as an international archival forum of scholarly research related to engineering and science education.
Investigations on the performance of diesel in an air gap ceramic coated dies...eSAT Journals
Abstract The world’s rapidly diminishing petroleum supplies, their raising costs and budding danger of environmental pollution have led to an intensive search for an alternative fuels or increasing the efficiency of the available diesel engines. It is a known fact that about 30% of energy supplied to the diesel engine is lost through the coolant and 30% is wasted through friction and exhaust and other losses, thus leaving only 40% of energy utilization for the useful purposes. If this lost heat rejection is reduced, the thermal efficiency can be improved. With the insulation of the combustion chamber Walls with ceramics, the transfer of heat can be restricted and can be used further for heating the incoming fresh charge and the same thing can be observed with exhaust gases. This increases the combustion efficiency and reduces the emissions. Hence in the present work, a ceramic coated engine is developed by incorporating air gap between the piston skirt and crown, cylinder liner and jacket, ceramic coating on cylinder head and valves. Therefore, a solemn attempt is made in this research work to investigate the performance and emission characteristics of diesel engine with diesel as fuel. Further the performance of the engine depends on the heat in the combustion chamber. This intends depend on piston material and the turbulence generated in the engine. So, further an attempt is made with brass piston insert and brass insert with six grooves which replaces the aluminum piston in the engine. Among all the pistons tested the brass insert with six grooves is proved to be the best in terms of performance and emissions point of view. But with the higher temperatures in the chamber drop in volumetric efficiency and lubricating oil deterioration are the main problems. However they can overcome by turbo compounding and with the development of new lubricants. Keywords: Ceramic engines, Air gap, New Lubricants, Piston inserts, Low heat rejection engines
IJRET : International Journal of Research in Engineering and Technology is an international peer reviewed, online journal published by eSAT Publishing House for the enhancement of research in various disciplines of Engineering and Technology. The aim and scope of the journal is to provide an academic medium and an important reference for the advancement and dissemination of research results that support high-level learning, teaching and research in the fields of Engineering and Technology. We bring together Scientists, Academician, Field Engineers, Scholars and Students of related fields of Engineering and Technology
Study of Thermal Stresses in High Temperature Brazing of Carbide to Steel San...AM Publications
Carbides and steels are two of the oldest established classes of technologically useful materials. While steel dominate engineering applications, carbides have some attractive properties compared to steels, which make them useful for specific applications. The properties of individual carbides and steels can vary widely; however, the characteristics of most materials in the two classes differ significantly. Joints between a steel and carbide are becoming increasingly important in the manufacturing of a wide variety of technological product. But joining carbide to steel materials often remains an unresolved or unsatisfactorily resolved problem such as thermal cracking, joint strength and carbide chip off. This paper deals with relieving the thermal stresses that are generated on carbides, it is found that use of sandwich alloy as filler metal minimizes the thermal stress on carbide.
Performance and emission charecterisatics of magnesia stabilized zirconia (mg...eSAT Journals
Abstract Demand for Fossil fuels has been increasing tremendously which cause environmental threat. For this reason a numerous studies are ongoing for renewable sources of energy worldwide. This paper investigates the effect of using TBC to diminish emissions from engine exhaust specifically nitrogen oxide and to augment the performance of the engine. Engine Components were coated with Mg-PSZ of which 150μm thinness of Zro2-24Mgo over a 50μm thickness of NiCrAlY bond. The input parameters considered for this study includes engine speed, compression ratio, stroke length and Neli oil. The output parameters such as thermal efficiency, Brake power, Brake Specific Fuel Consumption, Volumetric Efficiency and Emissions of NOx, CO, HC were studied in a thermal barrier coated engine running with Neli oil and diesel fuel blend. From this experiment it is observed that there is a significant improvement in the results of engine performance and emission characteristics. Key Words: Mg-PSZ, Plasma Spray Coating, Nelli Seed Oil, Diesel Engine, Emissions.
Geometric regeneration and mechanical analysis of a gas turbine blade type Fr...Barhm Mohamad
Simulation and visualization of the mechanical components have become a predominant phase
during the design and the production stages. Several means are used to improve the design and
to reduce study time. Today, the powerful hardware and the software available on the market
have contributed greatly on the improvement of design, visualization and manufacturing
process of complex parts (turbine blade). In this context, our study is a contribution to the
establishment of a methodology to a CAD modelling and finite element analysis, which allows
us to identify the mechanical behavior of a gas turbine blade. The profile of the blade turbine
model is obtained after regeneration using the CATIA V5R20 software from the retro-design
technique using a FARO-type scanner. The turbine blade is analyzed under a static mechanical
behavior. It has been observed that the maximum stresses and deformations are located in the
vicinity of the root and the upper surface along the turbine blade. On the other hand, the elastic
energy is located at a distance from the root of the turbine blade.
Modelling and Simulation of Composition and Mechanical Properties of High Ent...msejjournal
Magnesium alloys are high potential materials for application in the aerospace and automotive industries
due to their lightweight properties. They can help to lower dead weight and fuel consumption to contribute
to sustainability and efficiency. It is possible to achieve high specific strength and high stiffness of the
alloys by varying compositions of alloying elements. Applications of magnesium are limited due to its low
strength and relatively low stiffness. This research focuses on a recipe of multi component alloys of
magnesium with varied percentages of Mg, Al, Cu, Mn and Zn obtained from literature and optimizes the
percentage compositions to obtain for high specific strength and specific stiffness. Relationships among
percentage constituents of the alloy components are examined in Matlab R2022b using multiple linear
regression. Optimization is achieved using genetic algorithm to determine the specific strengths and
stiffness. The resulting optimal alloy component percentages by weight are used for microstructure
simulation of thermodynamic properties, diffusion and phase transformations of proposed alloy is done in
MatCalc software version 6.04. Results show potential for improved mechanical properties resulting from
disordered structure in the high entropy magnesium alloy. Future research should focus on production and
characterization of the proposed alloy.
Advances in Materials Science and Engineering: An International Journal (MSEJ)msejjournal
Advances in Materials Science and Engineering: An International Journal (MSEJ) is a quarterly open access peer-reviewed journal that publishes articles which contribute new results in all areas of the Materials Science and Engineering. The journal is devoted to the publication of high quality papers on theoretical and practical aspects of Materials Science and Engineering.
The goal of this journal is to bring together researchers and practitioners from academia and industry to focus on Materials Science and Engineering advancements, and establishing new collaborations in these areas. Original research papers, state-of-the-art reviews are invited for publication in all areas of Materials Science and Engineering.
More Related Content
Similar to Thermal and Metrological Studies on YTTRIA Stabilized Zirconia Thermal Barrier Coatings and a Simulated Model to Co-Relate the Findings
Since so many years a problem occurs in KSB Pump Va mbori for casting process i.e. cracks occurs in the castings & it is repeated one. Therefore the compan y has given opportunity to me to solve this problem . In case of steel casting there are mainly cracks & also blo w holes induced due to the casting procedure. There are many factors for the casting defects .The factor is unev en material feeding in casting & also due to the mo uld material & also the core material. These cracks finally brea k directly the component of the casting i.e. in cas e of pump the casting component is like Impeller,Volute casing & casing cover. At the time of feeding of steel material in to the casting the material is in liquid us form i.e. it i s hot material & this material is feeding into casting at the time o f feeding it develop different region of heat. At o ne side the temp is high &at other side the temp is low this also pr oduce cracks. To simulate that casting we use the M AGMA SOFTWARE for simulation & validate it using NDT.
Contact Pressure Validation of Steam Turbine Casing for Static Loading ConditionIJMER
International Journal of Modern Engineering Research (IJMER) is Peer reviewed, online Journal. It serves as an international archival forum of scholarly research related to engineering and science education.
Investigations on the performance of diesel in an air gap ceramic coated dies...eSAT Journals
Abstract The world’s rapidly diminishing petroleum supplies, their raising costs and budding danger of environmental pollution have led to an intensive search for an alternative fuels or increasing the efficiency of the available diesel engines. It is a known fact that about 30% of energy supplied to the diesel engine is lost through the coolant and 30% is wasted through friction and exhaust and other losses, thus leaving only 40% of energy utilization for the useful purposes. If this lost heat rejection is reduced, the thermal efficiency can be improved. With the insulation of the combustion chamber Walls with ceramics, the transfer of heat can be restricted and can be used further for heating the incoming fresh charge and the same thing can be observed with exhaust gases. This increases the combustion efficiency and reduces the emissions. Hence in the present work, a ceramic coated engine is developed by incorporating air gap between the piston skirt and crown, cylinder liner and jacket, ceramic coating on cylinder head and valves. Therefore, a solemn attempt is made in this research work to investigate the performance and emission characteristics of diesel engine with diesel as fuel. Further the performance of the engine depends on the heat in the combustion chamber. This intends depend on piston material and the turbulence generated in the engine. So, further an attempt is made with brass piston insert and brass insert with six grooves which replaces the aluminum piston in the engine. Among all the pistons tested the brass insert with six grooves is proved to be the best in terms of performance and emissions point of view. But with the higher temperatures in the chamber drop in volumetric efficiency and lubricating oil deterioration are the main problems. However they can overcome by turbo compounding and with the development of new lubricants. Keywords: Ceramic engines, Air gap, New Lubricants, Piston inserts, Low heat rejection engines
IJRET : International Journal of Research in Engineering and Technology is an international peer reviewed, online journal published by eSAT Publishing House for the enhancement of research in various disciplines of Engineering and Technology. The aim and scope of the journal is to provide an academic medium and an important reference for the advancement and dissemination of research results that support high-level learning, teaching and research in the fields of Engineering and Technology. We bring together Scientists, Academician, Field Engineers, Scholars and Students of related fields of Engineering and Technology
Study of Thermal Stresses in High Temperature Brazing of Carbide to Steel San...AM Publications
Carbides and steels are two of the oldest established classes of technologically useful materials. While steel dominate engineering applications, carbides have some attractive properties compared to steels, which make them useful for specific applications. The properties of individual carbides and steels can vary widely; however, the characteristics of most materials in the two classes differ significantly. Joints between a steel and carbide are becoming increasingly important in the manufacturing of a wide variety of technological product. But joining carbide to steel materials often remains an unresolved or unsatisfactorily resolved problem such as thermal cracking, joint strength and carbide chip off. This paper deals with relieving the thermal stresses that are generated on carbides, it is found that use of sandwich alloy as filler metal minimizes the thermal stress on carbide.
Performance and emission charecterisatics of magnesia stabilized zirconia (mg...eSAT Journals
Abstract Demand for Fossil fuels has been increasing tremendously which cause environmental threat. For this reason a numerous studies are ongoing for renewable sources of energy worldwide. This paper investigates the effect of using TBC to diminish emissions from engine exhaust specifically nitrogen oxide and to augment the performance of the engine. Engine Components were coated with Mg-PSZ of which 150μm thinness of Zro2-24Mgo over a 50μm thickness of NiCrAlY bond. The input parameters considered for this study includes engine speed, compression ratio, stroke length and Neli oil. The output parameters such as thermal efficiency, Brake power, Brake Specific Fuel Consumption, Volumetric Efficiency and Emissions of NOx, CO, HC were studied in a thermal barrier coated engine running with Neli oil and diesel fuel blend. From this experiment it is observed that there is a significant improvement in the results of engine performance and emission characteristics. Key Words: Mg-PSZ, Plasma Spray Coating, Nelli Seed Oil, Diesel Engine, Emissions.
Geometric regeneration and mechanical analysis of a gas turbine blade type Fr...Barhm Mohamad
Simulation and visualization of the mechanical components have become a predominant phase
during the design and the production stages. Several means are used to improve the design and
to reduce study time. Today, the powerful hardware and the software available on the market
have contributed greatly on the improvement of design, visualization and manufacturing
process of complex parts (turbine blade). In this context, our study is a contribution to the
establishment of a methodology to a CAD modelling and finite element analysis, which allows
us to identify the mechanical behavior of a gas turbine blade. The profile of the blade turbine
model is obtained after regeneration using the CATIA V5R20 software from the retro-design
technique using a FARO-type scanner. The turbine blade is analyzed under a static mechanical
behavior. It has been observed that the maximum stresses and deformations are located in the
vicinity of the root and the upper surface along the turbine blade. On the other hand, the elastic
energy is located at a distance from the root of the turbine blade.
Similar to Thermal and Metrological Studies on YTTRIA Stabilized Zirconia Thermal Barrier Coatings and a Simulated Model to Co-Relate the Findings (20)
Modelling and Simulation of Composition and Mechanical Properties of High Ent...msejjournal
Magnesium alloys are high potential materials for application in the aerospace and automotive industries
due to their lightweight properties. They can help to lower dead weight and fuel consumption to contribute
to sustainability and efficiency. It is possible to achieve high specific strength and high stiffness of the
alloys by varying compositions of alloying elements. Applications of magnesium are limited due to its low
strength and relatively low stiffness. This research focuses on a recipe of multi component alloys of
magnesium with varied percentages of Mg, Al, Cu, Mn and Zn obtained from literature and optimizes the
percentage compositions to obtain for high specific strength and specific stiffness. Relationships among
percentage constituents of the alloy components are examined in Matlab R2022b using multiple linear
regression. Optimization is achieved using genetic algorithm to determine the specific strengths and
stiffness. The resulting optimal alloy component percentages by weight are used for microstructure
simulation of thermodynamic properties, diffusion and phase transformations of proposed alloy is done in
MatCalc software version 6.04. Results show potential for improved mechanical properties resulting from
disordered structure in the high entropy magnesium alloy. Future research should focus on production and
characterization of the proposed alloy.
Advances in Materials Science and Engineering: An International Journal (MSEJ)msejjournal
Advances in Materials Science and Engineering: An International Journal (MSEJ) is a quarterly open access peer-reviewed journal that publishes articles which contribute new results in all areas of the Materials Science and Engineering. The journal is devoted to the publication of high quality papers on theoretical and practical aspects of Materials Science and Engineering.
The goal of this journal is to bring together researchers and practitioners from academia and industry to focus on Materials Science and Engineering advancements, and establishing new collaborations in these areas. Original research papers, state-of-the-art reviews are invited for publication in all areas of Materials Science and Engineering.
New Experiment System for the Interaction Between Soft Rock and Water : A Cas...msejjournal
The strength of rock strongly depends on the water content especially when the rocks contain clay
materials. The interaction between soft rock and water always threaten the soft rock engineering projects.
For this problem, new sets of laboratory experiment systems are developed to simulate the interaction
between soft rock and water or vapor. In this paper, the principles of experiment systems are introduced
with particular reference to the application on soft rock in Mogao Grottoes, one of the world famous
ancient sites in China. Two kinds of rock samples, the sandstone and muddy sandstone, are obtained by insitu sampling system. Then the laboratory experiments are performed under different environment
conditions. By the specific boundary conditions design, the physical-chemical effect and mechanic effect on
water absorption of rock samples are separated for further mechanism study by the experiment system, and
the different hydrological actions of water and vapor under variable experiment environment are obtained.
The interaction mechanism is discussed with assistant methods, such as SEM (Scanning Electron
Microscope), mercury injection test, X-ray diffraction analysis and etc. With the relation between water
content and soft rock strength, the study may provide guidance and basis for the soft rock engineering in
the future.
International Conference on Embedded Systems and VLSI (EMVL 2023)msejjournal
International Conference on Embedded Systems and VLSI (EMVL 2023) will provide an excellent International forum for sharing knowledge and results in theory, methodology and applications of Embedded Systems.
Advances in Materials Science and Engineering: An International Journal (MSEJ)msejjournal
Advances in Materials Science and Engineering: An International Journal (MSEJ) is a quarterly open access peer-reviewed journal that publishes articles which contribute new results in all areas of the Materials Science and Engineering. The journal is devoted to the publication of high quality papers on theoretical and practical aspects of Materials Science and Engineering.
Modeling, Analyzing and Safety Aspects of Torsion and Noise Effects on Round ...msejjournal
Each material has its own effect and behavior on external impacts like heat, force, tension, compression,
torsion etc. It is important to study and analyze these behaviors before selecting a material for an
engineering application in the design aspects itself. If predicted values analyzed by both mathematical and
software are available it is easy to get the reliable details in the pre design itself. By this one can ensure the
safety of the component and the system also. In this investigation, the effects of torsional loads on mild steel
round shafts with various diameters and lengths have been analyzed. The additional effects like angle of
rotation, rpm and duration also considered to find the optimum predicted value. The data observed by
various experiments are analyzed by design of experiments especially by response surface methodology.
Minitab software is used for canalization. The data are tabulated and kept for future reference. Noise effect
due to the gradual torsional load performed in the gear box and other rotating components is also studied
for healthy working environment. The nature and characteristics of material also be explained by this noise
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Advances in Materials Science and Engineering: An International Journal (MSEJ)msejjournal
Advances in Materials Science and Engineering: An International Journal (MSEJ) is a quarterly open access peer-reviewed journal that publishes articles which contribute new results in all areas of the Materials Science and Engineering. The journal is devoted to the publication of high quality papers on theoretical and practical aspects of Materials Science and Engineering.
The goal of this journal is to bring together researchers and practitioners from academia and industry to focus on Materials Science and Engineering advancements, and establishing new collaborations in these areas. Original research papers, state-of-the-art reviews are invited for publication in all areas of Materials Science and Engineering.
Advances in Materials Science and Engineering: An International Journal (MSEJ)msejjournal
Advances in Materials Science and Engineering: An International Journal (MSEJ) is a quarterly open access peer-reviewed journal that publishes articles which contribute new results in all areas of the Materials Science and Engineering. The journal is devoted to the publication of high quality papers on theoretical and practical aspects of Materials Science and Engineering.
On Decreasing of Dimensions of Field-Effect Transistors with Several Sourcesmsejjournal
We analyzed mass and heat transport during manufacturing field-effect heterotransistors with several
sources to decrease their dimensions. Framework the result of manufacturing it is necessary to manufacture
heterostructure with specific configuration. After that it is necessary to dope required areas of the heterostructure by diffusion or ion implantation to manufacture the required type of conductivity (p or n). After
the doping it is necessary to do optimize annealing. We introduce an analytical approach to prognosis mass
and heat transport during technological processes. Using the approach leads to take into account nonlinearity of mass and heat transport and variation in space and time (at one time) physical parameters of these
processes
Advances in Materials Science and Engineering: An International Journal (MSEJ)msejjournal
Advances in Materials Science and Engineering: An International Journal (MSEJ) is a quarterly open access peer-reviewed journal that publishes articles which contribute new results in all areas of the Materials Science and Engineering. The journal is devoted to the publication of high quality papers on theoretical and practical aspects of Materials Science and Engineering.
The goal of this journal is to bring together researchers and practitioners from academia and industry to focus on Materials Science and Engineering advancements, and establishing new collaborations in these areas. Original research papers, state-of-the-art reviews are invited for publication in all areas of Materials Science and Engineering.
Advances in Materials Science and Engineering: An International Journal (MSEJ)msejjournal
Advances in Materials Science and Engineering: An International Journal (MSEJ) is a quarterly open access peer-reviewed journal that publishes articles which contribute new results in all areas of the Materials Science and Engineering. The journal is devoted to the publication of high quality papers on theoretical and practical aspects of Materials Science and Engineering.
The goal of this journal is to bring together researchers and practitioners from academia and industry to focus on Materials Science and Engineering advancements, and establishing new collaborations in these areas. Original research papers, state-of-the-art reviews are invited for publication in all areas of Materials Science and Engineering.
Using Advanced Inspection Method (Three-Dimensional Ultrasonic) in Recognitio...msejjournal
In this study, using Harfang Code 32 device, the slag catcher pipelines in one of the South Pars phases
were tested. In radiography method of these lines, no clear defect was observed in radiographic films due
to the high thickness of 40 mm. However, marvelous results were obtained using advanced ultrasonic.
Review and analysis of the results will result in high potential of three-dimensional ultrasonic method in
identifying defects in pipelines with high thicknesses and preventing financial and life-threatening risks
during the use of these refineries in the future.
Advances in Materials Science and Engineering: An International Journal (MSEJ)msejjournal
Advances in Materials Science and Engineering: An International Journal (MSEJ) is a quarterly open access peer-reviewed journal that publishes articles which contribute new results in all areas of the Materials Science and Engineering. The journal is devoted to the publication of high quality papers on theoretical and practical aspects of Materials Science and Engineering.
RESULTS OF FINITE ELEMENT ANALYSIS FOR INTERLAMINAR FRACTURE REINFORCED THERM...msejjournal
The double cantilever beam (DCB) is widely used for fracture toughness testing and it has become popular
for opening-mode (mode I) delamination testing of laminated composites. Delamination is a crack that
forms between the adjacent plies of a composite laminate at the brittle polymer resin. This study was
conducted to emphasize the need for a better understanding of the DCB specimen of different fabric
reinforced systems (carbon fibers) with a thermoplastic matrix (EP, PEI), by using the extended finite
element method (X-FEM). It is well known that in fabric reinforced composites fracture mechanisms
include microcracking in front of the crack tip, fiber bridging and multiple cracking, and both contribute
considerably to the high interlaminar fracture toughness measured. That means, the interlaminar fracture
toughness of a composite is not controlled by a single material parameter, but is a result of a complex
interaction of resin, fiber and interface properties.
Advances in Materials Science and Engineering: An International Journal (MSEJ)msejjournal
Advances in Materials Science and Engineering: An International Journal (MSEJ) is a quarterly open access peer-reviewed journal that publishes articles which contribute new results in all areas of the Materials Science and Engineering. The journal is devoted to the publication of high quality papers on theoretical and practical aspects of Materials Science and Engineering.
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Woven hemp fabric was treated with sodium hydroxide, commercial flame retardant chemical, and
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Advances in Materials Science and Engineering: An International Journal (MSEJ) msejjournal
Advances in Materials Science and Engineering: An International Journal (MSEJ) is a quarterly open access peer-reviewed journal that publishes articles which contribute new results in all areas of the Materials Science and Engineering. The journal is devoted to the publication of high quality papers on theoretical and practical aspects of Materials Science and Engineering.
The goal of this journal is to bring together researchers and practitioners from academia and industry to focus on Materials Science and Engineering advancements, and establishing new collaborations in these areas. Original research papers, state-of-the-art reviews are invited for publication in all areas of Materials Science and Engineering.
Advances in Materials Science and Engineering: An International Journal (MSEJ) msejjournal
Advances in Materials Science and Engineering: An International Journal (MSEJ) is a quarterly open access peer-reviewed journal that publishes articles which contribute new results in all areas of the Materials Science and Engineering. The journal is devoted to the publication of high quality papers on theoretical and practical aspects of Materials Science and Engineering.
The goal of this journal is to bring together researchers and practitioners from academia and industry to focus on Materials Science and Engineering advancements, and establishing new collaborations in these areas. Original research papers, state-of-the-art reviews are invited for publication in all areas of Materials Science and Engineering.
Advances in Materials Science and Engineering: An International Journal (MSEJ)msejjournal
Advances in Materials Science and Engineering: An International Journal (MSEJ) is a quarterly open access peer-reviewed journal that publishes articles which contribute new results in all areas of the Materials Science and Engineering. The journal is devoted to the publication of high quality papers on theoretical and practical aspects of Materials Science and Engineering.
The goal of this journal is to bring together researchers and practitioners from academia and industry to focus on Materials Science and Engineering advancements, and establishing new collaborations in these areas. Original research papers, state-of-the-art reviews are invited for publication in all areas of Materials Science and Engineering.
Advances in Materials Science and Engineering: An International Journal ...msejjournal
Advances in Materials Science and Engineering: An International Journal (MSEJ) is a quarterly open access peer-reviewed journal that publishes articles which contribute new results in all areas of the Materials Science and Engineering. The journal is devoted to the publication of high quality papers on theoretical and practical aspects of Materials Science and Engineering.
The goal of this journal is to bring together researchers and practitioners from academia and industry to focus on Materials Science and Engineering advancements, and establishing new collaborations in these areas. Original research papers, state-of-the-art reviews are invited for publication in all areas of Materials Science and Engineering.
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Thermal and Metrological Studies on YTTRIA Stabilized Zirconia Thermal Barrier Coatings and a Simulated Model to Co-Relate the Findings
1. Advances in Materials Science and Engineering: An International Journal (MSEJ), Vol. 3, No. 2, June 2016
DOI:10.5121/msej.2016.3201 1
THERMAL AND METROLOGICAL STUDIES ON YTTRIA
STABILIZED ZIRCONIA THERMAL BARRIER COATINGS
AND A SIMULATED MODEL TO CO-RELATE THE
FINDINGS
Shankar. V1
, V.R. Reghu2
, Parvati Ramaswamy3
and KevinVattappara4
1
Professor & Principal Investigator, 2
Associate Professor and PhD Scholar,
3
Professor, and 4
Research Fellow
Surface Engineering Laboratory
Department of Mechanical Engineering, Faculty of Engineering, Christ University
Bangalore-560074, India
shankar.v@christuniversity.in
ABSTRACT
Thermal Barrier Coatings (TBCs), routinely prepared from Ceramic based compositions (typically
8%Y2O3-ZrO2or 8YSZ) are being engineered to protect the metallic components from degradation in
applications like gas turbines, jet and automotive engines. With a goal of finding improved TBC materials
a wide variety of ceramics are being researched worldwide. Before physically preparing the TBCs of
uncommon compositions in the laboratory, their suitability to perform can be predicted. Limited
accessibility to detailed and realistic information on the influence of newer compositions (other than 8YSZ)
on TBCs warrants methods to obtain this information.
In this paper, 8YSZ TBCs coated onto aluminium substratesare studied for thermal fatigue, thermal barrier
and materials characteristics to determine the reliability of the coating configuration to withstand the
harshness of test conditions under the framework of experiments. Thereafter, the results have been used to
corroboratethe developed simulation model. Results obtained via thermal tests confirm the suitability of the
model and we can predict the thermal barrier effects of TBCs when prepared from materials other than
YSZ.
KEYWORDS
Y2O3-stabilized Zirconia plasma sprayed TBCs, Structural phase analysis, TBC metrology, simulation
model of TBCs on aluminium substrate.
1. BACKGROUND INFORMATION
At the Mechanical Engineering Department, Faculty of Engineering Christ University, Bangalore,
one of the major research focuses is on diesel engine. Based on the submission of a research
proposal [1] and under the Major Research Project (MRP) scheme, an in-house funded project
has been sanctioned [2] during November 2013 by the Centre of Research Projects, Christ
University for a period of three years. The aim and objective in three phases is to a) create a state-
of-the-art facility catering to various class of diesel engines in the range of five to hundred HP
where in (i) five to ten HP single cylinder engines are used for irrigation and tiller applications
and (ii) sixty to eighty HP class four cylinder engines are used for light motor vehicle
2. Advances in Materials Science and Engineering: An International Journal (MSEJ), Vol. 3, No. 2, June 2016
2
applications, b) evaluate the base line engine characteristics by extensive testing and endurance
testing and c) work on engine modification by going in for Low Heat Rejection (LHR) engine
with the idea of providing value added inputs on the existing engine in terms of better Specific
Fuel Consumption (SFC) and reduced pollutants.
Research work is in good progress and LHR engine is realized by Thermal Barrier Coating (TBC)
of piston crown. Before coating on the actual piston, coating trials are in progress on aluminium
plates, fabricated research pistons and tested for thermal barrier and thermal shock in in-house
developed laboratory scale burner rig facility at the Surface Engineering Laboratory. Coatings
also would be tested for adherence before implementing on the piston crown. Additional work
involves development of simulation model and study of coating metrology to correlate the
findings with any newer compositions that may be researched in the future.
About a dozen thrust areas are identified. Over half a dozen research faculties from various
departments – Mechanical, Electrical, Electronics, Mathematics and Chemistry departments
participate in this interdisciplinary research program along with thirty undergraduate research
students. The potential includes: a) faculty pursuing Ph.D, b) Students performing research after
prescribed academic hours and turning out project/fellowship reports and c) vendor development
for associating with research work. While Amado Toolsand Spraymet industries in Bangalore are
involved in fabrication of research components and plasma spraying activities respectively, the
material characterization activities are supported by the Central Manufacturing Technology
Institute (CMTI), Bangalore. The establishment and maintenance of diesel engine test rigs and
laboratory burner rig is being managed by the involvement of Tech Ed Industries, Bangalore.
2. INTRODUCTION
In this paper, focus is on the applicability of TBCs on automotive components and therefore
aluminium as the underlying metal.The technology and advantages of thermal barrier coatings
(TBCs) on the hotter side of diesel or turbine engine components, although are well-established
and accepted,the adaptability of these ceramics in different applications are still being pursued
actively. Ceramic coatings are being considered for diesel engine cylinder liners, piston caps,
valve faces and seats, piston rings, and other parts and for turbine components such as
combustors, blades, stators, seals, and bearings.TBC’s have been used to simulate adiabatic
engines with the intention not only for reduced in-cylinder heat rejection and thermal fatigue
protection of underlying metallic surfaces, but also for possible reduction of engine emissions[3
to 5].The operating efficiency of propulsion and power generation devices (such as diesel
engines, gas turbines and jet engines) increases with their operating temperature [6].
The application of TBC’s are expected to reduce the heat transfer to the engine cooling jacket
through the combustion chamber surfaces (which include the cylinder head, liner and piston
crown) and piston rings. The insulation of the combustion chamber with this coating, which is
mainly ceramic based, influences the combustion process and hence the performance and exhaust
emission characteristics of the engines. The former is easily understood from the first law of
Thermodynamics, although the reduction in cylinder heat rejection may not favourably convert
into a useful mechanical work but rather as an increased waste heat in the engine exhaust. The
latter is extremely complicated because the increased air (or fuel-air mixture) temperature, due to
the TBC (before the onset of combustion), could alter the ignition characteristic of the fuel-air
mixture and its subsequent reaction mechanism, which are directly related to the exhaust emission
characteristics. Moreover, the thermo physical properties of the coated ceramic and its surface
roughness and pore characteristics (Number and Size), have a direct influence on un-burnt or
partially burnt hydrocarbons through the surface quenching effect and their residence in the pores.
3. Advances in Materials Science and Engineering: An International Journal (MSEJ), Vol. 3, No. 2, June 2016
3
The desire to increase thermal efficiency or reduce fuel consumption of engines makes it
attractive to adopt higher compression ratios, in particular for diesel engines and reduced in-
cylinder heat rejection. Both these factors lead to an increase in mechanical and thermal stresses.
The durability concerns for the materials and components in the engine cylinders, which include
piston, rings, liner and cylinder head, limit the allowable in-cylinder temperatures [7].
Application of TBC’s to the surfaces of these components enhances high temperature durability
by reducing the heat transfer and lowering temperatures of the underlying metal.Although 8YSZ
is routinely applied as a TBC material, search is on for newer compositions that will offer
improved coating configuration involving adhesion, thermal barrier and shock properties etc.
Many different kinds of ceramic materials and processes are being researched worldwide for
finding a material and process configuration superior to the most popular TBC 8YSZ. By using
pyrochlores (A2
3+
B2
4+
O7 where A sites are Dy, La and Sm in place of Y) or perovskites such as
SrZrO3, reduced heat transfer and improvement in barrier properties have been observed by
many researchers [8 to 13].However,involvement of the use of ceramic materials as TBC’s has
revealed widely differing aspects in practical applications[14].Partially/Fully Stabilized Zirconia
(PSZ/FSZ)has excellent toughness, hot strength and thermal shock resistance, low thermal
conductivity and a thermal expansion coefficient close to those of steel and cast iron. PSZ has
been widely used as a TBC in the combustion of diesel engines [15, 16]. However,
contradicting reports also do exist which questions the dominance of a TBC on an
application.The applicability of TBC to Spark Ignition (SI) engine and Compression Ignition (CI)
Engine is discussed in the paper bySivakumar and Shankar [17]. Hari [18] discusses the effect of
TBC on eleven HP class engine. Kevin Vattappara[19] discussesyttria stabilized zirconia as TBC
on metal substrates. Shankar et.al [20] have reported the results of their findings on the lab scale
preparation and evaluation of yttria stabilized zirconia thermal barrier coatings and its influence
on the diesel engine performance. Reghu [21] discusses TBC development on piston crown and
simulation of LHR engines.
3. SCOPE OF THE PRESENT INVESTIGATION
The present investigation focuses on rectangular/square shapedaluminium substrates. TBCs with
thickness between 200 microns and upto300 microns were prepared on 50-100 micron thick
Nickel Aluminide (NiAl) bond coated aluminium substrates. Therefore the results presented here
pertain to varying TBC thicknesses. The TBCs were prepared from 8%Y2O3-ZrO2 plasma
sprayable powders(prepared in the laboratory by using organic binders), coated onto 100 mm x
100 mm x 3 mm thickaluminium substrates, and subjected to thermal stress (thermal shock)
cycles, evaluated for number of such heat-quench cycles they could withstand (or a
predetermined number of stress cycles) before failure/visual degradation, and thermal barrier
characteristics. Both the tests were carried out by using a Surface Engineering Laboratory-
designed and developed simulated burner rig facility. The as-sprayed and thermal tested
specimens were subjected to Metrological studies.
The results obtained from the above tests were corroborated by a simulation model which
involved the usage of parameters such as coating thickness, thermal conductivity, specific heat,
and density as boundary conditions.
3.1. Thermal Barrierand Thermal ShockTests
The thermal barrier test involved exposing the ceramic coated surface with a high temperature
flame focused on the centre of the coated specimen, allowing the ceramic surface sufficient time
(~ 2 hours) to attain the intended stabilized temperature under the steady flame conditions (flame
temperatures (T) varying from 250 upto 6300
C, (melting point of Aluminium: 6600
C) at regular
4. Advances in Materials Science and Engineering: An International Journal (MSEJ), Vol. 3, No. 2, June 2016
4
∆T of ~100 degrees). The substrate temperature at the back of the specimen was measured to an
accuracy of + 5 degrees.
The thermal shock test involved exposing the ceramic surface to 6500
C for a pre-fixed amount of
time (5 minutes) and suddenly withdrawing the specimen to face a blast of cold air to rapidly
quench the hot ceramic surface including the aluminium substrate; thereafter reintroducing the
ceramic surface to the flame after five minutes hold at the relatively colder ambient. The numbers
of such heat quench cycles were recorded to assess the suitability of the TBC to protect the
aluminium substrate from such an extremely harsh thermal environment. Figure.1 shows the test
facility along with a coated substrate.
Figure 1. Simulated Burner Rig Test Facility at FECU with a typical Thermal Barrier Coated substrate
mounted on test set-up.
3.2. Metrological Studies on the TBCs
The plasma sprayed aluminium plates, with as-sprayed coatings and after undergoing thermal
stress tests were subjected to the following metrological tests.
• Structural phase analysis
• Microstructure analysis on metallographic cross section specimen
3.2.1. Structural phase analysis: the structural phase analysis was carried out on the ceramic
surface by employing the X-ray Diffractometer (XRD). The TBC surface was scanned
between 2θ values of 20 and 100 degrees.
3.2.2.Determination of c/t- ZrO2 phase: The percentage of stabilization of the cubic/tetragonal
(c/t) and monoclinic (m) zirconia was determined from the {111} family of planes by using the
following equation:
%m-ZrO2 = Im (111) + Im(11ī)
Im (11ī) + Im(111) + It(111)
%c/tZrO2 = 1- %m-ZrO2
Where, m=monoclinic, t=tetragonal, I=intensity
5. Advances in Materials Science and Engineering: An International Journal (MSEJ), Vol. 3, No.
3.2.2. Microscopy:The coating stability before (as
was determined by visually
and the (ii) substrate with bond coat as well.
metallographic cross section of the
Cracks generated during the thermal stress testing
cohesive/adhesive failure, delamination
analysis. The TBC surface also was
3.3. Simulation Model Involving TBCs
The prime role of a TBC is to introduce a temperature drop across the thickness of the coating by
the merit of the thermal insulation characteristics it possesses. In addition to the thermal
conductivity, the other contributing characteristics are :
Surface Temperature, (c) Coating and Substrate Specific Heat
Ambient Environment Conditions.
These parameters have been used to simulate a model in order to be able to predict the ability of
the 8YSZ coatings to function as TBC’s as well as their efficiency in terms of temperature drop
across the coating.
The model of the TBC coated substrate was prepared
Then the model was imported into Hypermesh 13.0 and meshed with each zone being done
separately. The meshed model was
given its material properties and it was simulated for different temperatures (varying from 250
up to 6500
C, at regular ∆T of ~100 degrees). A suitable ambient temperature higher than room
temperature was incorporated in the model which varied with each
4. SALIENT FINDINGS
4.1: Thermal Barrier and Thermal Shock tests
4.1.1: Thermal Barrier Test:Fig.
section 3.1 and Fig.1.
Advances in Materials Science and Engineering: An International Journal (MSEJ), Vol. 3, No. 2, June
The coating stability before (as –sprayed) and after the thermal stress test
visually studying the adhesion of the (i) ceramic with the bond coat
and the (ii) substrate with bond coat as well. The study was conducted on the
cross section of the plates ina Scanning Electron Microscope (SEM).
racks generated during the thermal stress testing, formation of any defects including
cohesive/adhesive failure, delamination, macro defects etc. also were addressed in this
The TBC surface also was examined.
Simulation Model Involving TBCs
The prime role of a TBC is to introduce a temperature drop across the thickness of the coating by
lation characteristics it possesses. In addition to the thermal
ributing characteristics are : (a) Coating Thickness,
(c) Coating and Substrate Specific Heat, (d) Density and finally (e) the
mbient Environment Conditions.
used to simulate a model in order to be able to predict the ability of
coatings to function as TBC’s as well as their efficiency in terms of temperature drop
el of the TBC coated substrate was prepared by using the Solid Edge V18 platform.
Then the model was imported into Hypermesh 13.0 and meshed with each zone being done
meshed model was then imported to Ansys Fluent 14.5, where the model was
given its material properties and it was simulated for different temperatures (varying from 250
T of ~100 degrees). A suitable ambient temperature higher than room
temperature was incorporated in the model which varied with each rise in temperature.
FINDINGS
: Thermal Barrier and Thermal Shock tests
Fig.2 shows the test results of the thermal barrier tests described in
2, June 2016
5
sprayed) and after the thermal stress test
studying the adhesion of the (i) ceramic with the bond coat
The study was conducted on the
plates ina Scanning Electron Microscope (SEM).
any defects including
, macro defects etc. also were addressed in this
The prime role of a TBC is to introduce a temperature drop across the thickness of the coating by
lation characteristics it possesses. In addition to the thermal
, (b) Coating
(d) Density and finally (e) the
used to simulate a model in order to be able to predict the ability of
coatings to function as TBC’s as well as their efficiency in terms of temperature drop
Solid Edge V18 platform.
Then the model was imported into Hypermesh 13.0 and meshed with each zone being done
imported to Ansys Fluent 14.5, where the model was
given its material properties and it was simulated for different temperatures (varying from 2500
C
T of ~100 degrees). A suitable ambient temperature higher than room
rise in temperature.
shows the test results of the thermal barrier tests described in
6. Advances in Materials Science and Engineering: An International Journal (MSEJ), Vol. 3, No. 2, June 2016
6
Figure 2. Thermal barrier test results –Temperature drop across the TBC with the Ceramic Surface at the
High temperature shown in the X-Axis (C)
4.1.2: Thermal Shock Test
The TBC, described in the previous section was subjected to more than 500 heat – quench cycles
before the test was stopped. At the end of 500 cycles with the ceramic surface temperature
maintained at 630o
C, visual inspection of the TBC showedrevealed no degradation or cracking of
the top coat and no detachment from the substrate.
In order to provide a very harsh test condition, and to explore if higher flame temperature at the
ceramic surface would provide the much needed thermal stress to delaminate the coating from the
substrate, the flame temperature was increased to about 8000
C for a brief period of 3
minutes.With an anticipated temperature drop of ~130o
C, the metal substrate was expected to
briefly experience a temperature of ~670o
C (800-130o
C =670o
C), higher than the melting
temperature of aluminium (660o
C) and thus the onset of melting would occur.Yet, at the end of
this experiment, no spalling of the coating was observed. This sample was studied further for
structural phase change and microstructure.
4.2 Metrological Studies on the TBCs
4.2.1 Structural phase analysis: Figure 3 shows the XRD pattern of (a) surface of the as-
sprayed coating and (b) the surface after subjected to 500 thermal stress cycles between
650o
C and ambient.
(a) XRD pattern of as sprayed TBC (b)XRD pattern of TBC after thermal stress test
(500 heat quench cycles between 650o
C and ambient)
Figure 3. XRD Patterns (2θ between 20 and 100 degrees)
XRD patterns shown above exhibit the presence of two zirconia phases:cubic /tetragonal (c/t) and
monoclinic (m) zirconia. The 100% c/t-ZrO2 is reflected at the 2θ=30 degrees peak in the
pattern. The two peaks adjacent to the major c/t-ZrO2 peak belong to the m-ZrO2. All the three
peaks around 2θ=30 degrees, belong to the {111} family of planes of ZrO2. The desired phase of
TBC application is c/t-ZrO2.
Presence of ~87% of c/t-ZrO2 calculated from the XRD pattern shown in Figure 3(a) confirmed
the stabilization of the desired phase in as-sprayedYSZ TBC. As expected ,the thermal shock
cycling test did not introduce any significant de-stabilization effects as evident from the XRD
Lin
(Counts)
0
1000
2000
3000
4000
5000
6000
7000
8000
9000
10000
11000
12000
13000
14000
15000
16000
17000
18000
19000
20000
21000
22000
2-Theta - Scale
20 30 40 50 60 70 80 90 100
Lin
(Counts)
0
1000
2000
3000
4000
5000
6000
7000
8000
9000
10000
11000
12000
13000
14000
15000
16000
17000
2-Theta - Scale
20 30 40 50 60 70 80 90 100
7. Advances in Materials Science and Engineering: An International Journal (MSEJ), Vol. 3, No.
pattern shown in Figure 3(b). This is because; temperature in the vicinity of 700
enough to destabilize the c/t-ZrO
ZrO2 in pattern after thermal stress cycling to be ~85%.
4.2.2 Microstructure analysis on cross sectional metallographic specimen
Figure 4 shows the as-sprayed TBC in a metallographic polished cross
Figure 4. SEM
Detailed metallographic cross-section analysis of the as
defect free ceramic bond coat and bond coat substrate interface. The coating thickness varied
between 180 and 210 microns with an average thickness of about 200 micr
(average) NiAl bond coat. The defects s
during the process of grinding and polishing.
(a)
Figure 5.SEM micrograph
The as-sprayed surface shown in Figure 5 (a and b),
typically during the process of plasma spraying as consequence of stresses generated within the
ceramic during rapid cooling.
Surprisingly, cross section metallography of the thermal stress cycled specimen
6.revealed a microstructure no different from the as
Advances in Materials Science and Engineering: An International Journal (MSEJ), Vol. 3, No. 2, June
This is because; temperature in the vicinity of 7000
C was not
ZrO2 phase during the experiment. The calculations revealed %c/t
in pattern after thermal stress cycling to be ~85%.
Microstructure analysis on cross sectional metallographic specimen
sprayed TBC in a metallographic polished cross-section.
Figure 4. SEM micrograph for the as-sprayed sample
section analysis of the as-sprayed TBC revealed a smooth and
defect free ceramic bond coat and bond coat substrate interface. The coating thickness varied
with an average thickness of about 200 microns on 100 microns
The defects seen in ceramic top coat are attributed to grain pull
during the process of grinding and polishing.
(b)
SEM micrograph of TBC as sprayed surface at (a) 1000X and (b) 5000X.
shown in Figure 5 (a and b), exhibited several micro-cracks generated
typically during the process of plasma spraying as consequence of stresses generated within the
Surprisingly, cross section metallography of the thermal stress cycled specimen shown in Figure
revealed a microstructure no different from the as-sprayed specimen. Smooth defect free
2, June 2016
7
C was not high
The calculations revealed %c/t-
sprayed TBC revealed a smooth and
defect free ceramic bond coat and bond coat substrate interface. The coating thickness varied
ons on 100 microns
are attributed to grain pull-out
of TBC as sprayed surface at (a) 1000X and (b) 5000X.
cracks generated
typically during the process of plasma spraying as consequence of stresses generated within the
shown in Figure
sprayed specimen. Smooth defect free
8. Advances in Materials Science and Engineering: An International Journal (MSEJ), Vol. 3, No. 2, June 2016
8
topcoat-bondcoat and bond coat-aluminum substrate interface showed minimum to least amount
of oxidation of the metals/bond coat alloy. Although aluminium melts at 660o
C, there were no
signs of any melting or deformation when the TBCs on aluminum were exposed to the high flame
temperature of 630o
C. Even then the aluminium substrate has not undergone any deformation.
Figure 6. SEM micrograph of TBC on thermally stressed surface.
Thermal barrier tests have shown a maximum temperature drop of about 130o
C across the TBC.
Thus it is expected that the temperature experienced by the underlying metal substrate has not
crossed about 500o
C during the planned thermal shock cycling testing. The specimen has been
exposed to a flame at 650o
C for nearly 40 hours .
In addition, the ceramic surface was also exposed to 8000
C briefly for about 3 minutes, which
means the underlying metal was exposed to a temperature of about 6700
C, which is beyond the
melting temperature of aluminium.Closer examination of the bond coat-substrate interface
revealed isolated pockets of crack network. This is attributed to the flexing of the metal substrates
in some position to the extreme (induced) thermal stress it has undergone and yet the coating did
not peel off the substrate. A typical micrograph is shown in Figure 7.
Figure 7. SEM cross section micrograph of TBC on thermally stressed surface
revealing cracks the aluminium-bond coat interface.
This experiment confirms the soundness of the TBCs and the coating configuration.
9. Advances in Materials Science and Engineering: An International Journal (MSEJ), Vol. 3, No. 2, June 2016
9
4.3: Simulation Model Involving TBCs
A simulation model was developed to corroborate the results of the thermal stress tests. Generally
the most commonly used TBCs are about 300 micron thick with bond coats of 50 micron
thickness. Therefore, the model developed pertains to such a coating configuration. In the future,
it is planned to further build the models and predict the results of newer TBC configurations with
compositions other than 8YSZ.
4.3.1 Simulation Model Development
Figure 8.shows a snapshot of a part of the model developed for the TBC on aluminium
substrate with 300 micron thick coating on 50 micron thick Nickel Aluminide (NiAl)
bond coat including an area of Air Domain using Solid Edge V18® simulation software.
Figure 8: Snapshot of a part of the model developed
4.3.2Figure 9. (a through e) shows the temperature contours showing the ∆T across the thickness
of the TBC, bond coat and substrate.
(a) Temperature Contour for 2500
C (523 K)
10. Advances in Materials Science and Engineering: An International Journal (MSEJ), Vol. 3, No. 2, June 2016
10
(b) Temperature Contour for 3500
C (623K)
(c) Temperature Contour for 4500
C (723K)
(d) Temperature Contour for 5500
C (823K)
11. Advances in Materials Science and Engineering: An International Journal (MSEJ), Vol. 3, No. 2, June 2016
11
(e) Temperature Contour for 6300
C (903K)
Figure 9. (a through e): Temperature Contours showing the
∆T across the thickness of the TBC, bond coat and the substrate.
The temperature contours shown in temperature scale (depicted in Kelvin Scale) in each Figure of
9 (a through e ) signify the range of temperature (room temperature to the maximum attained for
the particular experiment) under investigation. The maximum temperature set for these
experiments were 2500
C (Figure 9 a), 3500
C (Figure 9b), 4500
C (Figure 9 c), 5500
C (Figure 9 d)
and 6300
C (Figure 9 e).
The temperature drop across the thickness of the coatings (350 microns), substrate (3.0 mm) and
air domain (~ 20.0 mm) in each temperature contour is shown separately in the above figures
(Figure 9. (a through e)). The same results are depicted in graphical form in the following figures.
4.3.3Contour Plots
Figure 10. (a through e) shows the graphs pertaining to the temperature contours of the ∆T across
the thickness of the TBC, bond coat and substrate, shown in Figure 9. (a through e).
(a) Graph for 2500
C (523K)
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(b) Graph for 3500
C (623K)
(c) Graph for 4500
C (723K)
(d) Graph for 5500
C (823 K)
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(e) Graph for 6300
C (903 K)
Figure 10. (a through e): Graphs pertaining to temperature contours showing the
∆T across the thickness of the TBC, bond coat and substrate.
4.4 Summary of Experimental Results
Thermal barrier coatings (TBCs) from laboratory processed plasma sprayable powders from
8Y2O3-stabilized zirconia were prepared on rectangular aluminum plates. The plates were
subjected to thermal stress and barrier tests and the severly heat affected plates were evlauated for
structural phase and microstructural degradation. None were found and the results confirmed that
the coatings were of good quality.
In order to predict the potential of new compositions that would be devloped in the laboratory for
possible TBC applications in the future, a simulation model was developed by incorporating the
results obtained in this work.
5.CONCLUSION
In this paper, results of thermal stress tests on aluminum plates coated with 8YSZ TBCs are
presented along with temperature contours simulation models after corroboration with the test
results.The coatings have exhibited no degradation when tested with burner rig flame surface
temperature as high as 6300
C thereby indicating that the aluminium plate was in principle
exposed to a flame close to its melting temperature for nearly 40 hours without showing any signs
of failure. This is because the aluminium plate was actually experiencing a temperature of only
5000
C because of the thermal barrier effects provided by the 8YSZ TBC. The simulation models
are expected to provide a framework for exploring the potential of TBCs with newer
compositions prior to actually beginning the TBC preparation process in the practically rigorous
way.
Work is in progress towards coating trials on specially fabricated research piston to finalize the
optimum coating parameters and implement LHR concept in four cylinder engine. Adequate
number of thermal barrier and thermal shock tests would be carried out on research pistons,prior
to the implementation of LHR concept in four cylinder engine.
6. ACKNOWLEDGEMENT
Authors would like to acknowledge with thanks the Christ University Management headed by
Vice Chancellor, Dr. (Fr.) Thomas C Mathew, Engineering Director Fr. Benny Thomas,
Associate Director (Centre for Research–Projects) Prof. D.N.S Kumar, Associate Dean, Faculty
of Engineering Dr. Iven Jose and Mechanical Department Co-Ordinator Dr. Gurumoorthy
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Hebbar for encouraging R & D work.Discussions with Dr. Ganesan V., (Retired Professor, IIT
Madras) and presently visiting faculty at Christ University are acknowledged.Authors would like
to acknowledge with thanks the work on conjugate heat transfer by Mechanical Engineering
Department, Assistant Professor and Research Faculty Mr. Thejaraju.
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