Heat Loss Analysis of a Steel Piston and a YSZ Coated Piston in a Heavy-Duty Diesel Engine Using Phosphor Thermometry Measurements

Binder, Christian; Nada, Fahed Abou; Richter, Mattias; Cronhjort, Andreas; Norling, Daniel

doi:10.4271/2017-01-1046

Cited by 28 publications

(13 citation statements)

References 26 publications

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“…A very large part of the recent literature still concerns Diesel engines developed either for heavy-duty [3][4][5] or light-duty applications [6][7][8]. Several recent nationally funded projects are also considering compression ignition engines using steel or aluminum pistons [9,10].…”

Section: Introductionmentioning

confidence: 99%

“…Yttria Stabilized Zirconia (YSZ) which was one of the most applied Thermal Barrier Coating in the 1980s was considered once again more recently by Binder et al [3] for a fundamental study combining direct flame visualization and piston surface temperature measurements with an heavy-duty single cylinder engine using a steel base piston. Uchida and Osada [4] also reported the results of an extensive study using Zirconia based insulation coatings applied on the steel piston of an heavy-duty single cylinder engine.…”

Section: Introductionmentioning

confidence: 99%

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Experimental assessment of new insulation coatings for lean burn spark-ignited engines

Cherel

Zaccardi

Bouteiller

et al. 2020

Oil Gas Sci. Technol. – Rev. IFP Energies nouvelles

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Clean and highly efficient internal combustion engines will still be necessary in the future to meet the ambitious CO2 emissions reduction targets set for light-duty vehicles. The maximal efficiency of stoichiometric Spark-Ignited (SI) gasoline engines has been steadily increasing in recent years but remains limited by the important relative share of cooling losses. Low heat rejection engines using ceramic barrier coatings have been presented in the past but smart insulation coatings are gaining a renewed interest as a more promising way to further increase the engine maximal thermal efficiency. This article is highlighting some important effects of smart insulation coatings developed for lean-burn spark-ignited gasoline engines. Five different coatings with low heat conductivity and capacity are applied on aluminum engine parts with the atmospheric plasma spray technique and are tested with two different engines. The laser induced phosphorescence technique is firstly used in an optical single cylinder engine to quantify the thermal performance of these coatings in terms of temperature swing during combustion. A maximal increase in the piston surface temperature of around 100 °C is measured at low load, confirming thus the expected impact of the low heat conductivity and capacity, and suggesting thus a positive impact on fuel consumption. Thanks to the tests performed with a similar metal single cylinder engine, it is shown that the unburned hydrocarbon emissions can significantly increase by up to 25% if the open porosity on top of the coating is not properly sealed, while the surface roughness has no impact on these emissions. When applied on both the piston and the cylinder head, the optimized coating displays some distinct effects on the maximal heat release rate and NOx emissions, indicating that the thermal environment inside the combustion chamber is modified during combustion. Thanks to the temperature swing between cold and hot engine phases the volumetric efficiency can also be kept constant. However, no increase in efficiency can be measured with this optimized coating which suggests that the heat balance is not affected only by the reduction in the temperature differential between the walls and the gas.

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Section: Introductionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Experimental assessment of new insulation coatings for lean burn spark-ignited engines

Cherel

Zaccardi

Bouteiller

et al. 2020

Oil Gas Sci. Technol. – Rev. IFP Energies nouvelles

View full text Add to dashboard Cite

show abstract

“…An important limitation of this type of coating material, the most common being the partially stabilized zirconia (PSZ), was a decrease in volumetric efficiency. 15,16 Indeed, due to their relatively high heat capacity, the insulated wall was remaining at a high temperature during the entire cycle, causing an increase in intake air temperature. A way to tackle this issue was recently proposed by Toyota Central R&D Labs and Toyota Motor Corporation.…”

Section: Introductionmentioning

confidence: 99%

“…Current research efforts continue in this direction. If surface temperature and heat flux measurements are crucial to characterize the efficiency of a coating, 15,23–25 simulations remain a convenient tool to evaluate a large range of coating materials and optimize their thickness and location. Zero-dimensional and one-dimensional (1D) platforms have been widely implemented.…”

Section: Introductionmentioning

confidence: 99%

Modeling investigation of thermal insulation approaches for low heat rejection Diesel engines using a conjugate heat transfer model

Poubeau

Arthur

Duffour

et al. 2018

International Journal of Engine Research

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Heat losses through combustion chamber walls are a well-known limiting factor for the overall efficiency of internal combustion engines. Thermal insulation of the walls has the potential to decrease substantially these heat losses. However, evaluating numerically the effect of coating and of its location in the combustion chamber and then design an optimized combustion system require the use of high-fidelity engine models. The objective of this article is to present the whole workflow implying the use of three-dimensional computational fluid dynamics techniques with conjugate heat transfer (CHT) models to investigate the potential benefits of a coating on a passenger car Diesel engine. First, the baseline combustion system is modeled, using CHT models to solve in a coupled simulation the heat transfers between the fluid in the intake and exhaust lines and in the combustion chamber, on one hand, and the solid piston, head and valves, on the other hand. Based on this setup, a second simulation is performed, modeling a thermo-swing insulation on all combustion chamber walls by a contact resistance, neglecting its thermal inertia to keep a manageable computational cost. Results show a decrease of 3.3% in fuel consumption with an increase in volumetric efficiency. However, decoupled one-dimensional/three-dimensional simulations highlight the inaccuracy of these results and the necessity to model the coating thermal inertia, as they show an overestimation of the heat insulation rate and, consequently, of the gain in fuel consumption (−2.1% instead of −1.6%), for a coating on the piston with no thermal inertia.

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“…Ceramic-based coatings, usually of yttria-stabilized zirconia (YSZ), have been explored as a means of insulating the combustion chamber surfaces. Applied on a heavy duty diesel engine piston, these coatings have been demonstrated to reduce the instantaneous piston heat flux [4]. However, the expected benefits on thermal efficiency were not seen likely due to a penalty in volumetric efficiency resulting from the higher cylinder surface temperatures throughout the cycle [5,6].…”

Section: Introductionmentioning

confidence: 99%

Thermal Analysis of Steel and Aluminium Pistons for an HSDI Diesel Engine

Papaioannou¹,

Leach²,

Davy³

2019

SAE Technical Paper Series

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Chromium-molybdenum alloy steel pistons, which have been used in commercial vehicle applications for some time, have more recently been proposed as a means of improving thermal efficiency in lightduty applications. This work reports a comparison of the effects of geometrically similar aluminium and steel pistons on the combustion characteristics and energy flows on a single cylinder high-speed direct injection diesel research engine tested at two speed / load conditions (1500 rpm / 6.9 bar nIMEP and 2000 rpm / 25.8 bar nIMEP) both with and without EGR. The results indicate that changing to an alloy steel piston can provide a significant benefit in brake thermal efficiency at part-load and a reduced (but nonnegligible) benefit at the high-load condition and also a reduction in fuel consumption. These benefits were attributed primarily to a reduction in friction losses. In terms of energy transfer, switching to the steel piston design was shown to reduce heat transfer to the coolant, consistent with lower friction work and reduced conduction through the ring pack, and increase the energy transfer to the oil. Piston blowby was also greatly reduced. Ignition delay times and overall combustion durations were reduced with the steel piston design, possibly indicative of higher piston surface temperatures.

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Heat Loss Analysis of a Steel Piston and a YSZ Coated Piston in a Heavy-Duty Diesel Engine Using Phosphor Thermometry Measurements

Cited by 28 publications

References 26 publications

Experimental assessment of new insulation coatings for lean burn spark-ignited engines

Experimental assessment of new insulation coatings for lean burn spark-ignited engines

Modeling investigation of thermal insulation approaches for low heat rejection Diesel engines using a conjugate heat transfer model

Thermal Analysis of Steel and Aluminium Pistons for an HSDI Diesel Engine

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