Investigation Of IC Engine Part With Coating A Review

International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395 -0056
Volume: 04 Issue: 02| Jan -2017 www.irjet.net p-ISSN: 2395-0072
© 2017, IRJET | Impact Factor value: 5.181 | ISO 9001:2008 Certified Journal | Page 1009
Investigation Of IC Engine Part With Coating A Review
Ravi S Modi1, Maulik Modi2, Dr. Tushar M Patel 3
1ME scholar, Mechanical Department,LDRP-ITR,Gandhinagar,India.
2Assistant Professor,Mechanical Department,LDRP-ITR,Gandhinagar,India
3Professor,Mechanical Department, LDRP-ITR, Gandhinagar,India
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Abstract - Piston is most important part inautomobileengine
in which it helps to convert the chemical energy liberated by
the combustion of fuel into useful mechanical power. The
performance ic engine is depends on piston size and working
in dynamic conditions. So, the piston is a heart of the icengine.
The internal combustion engines piston made of Aluminum
alloy, stainless steel, cast iron etc. When the combustionoffuel
charge takes place inside combustion chamber, high pressure
and high temperature are developed due to combustion of the
fuel. Because of high loads, the piston is subjected to high
thermal stress and mechanicalstresses. Ifthesestressesexceed
the designed values, failure of piston may take place.
Temperature, operating gas pressure and materialproperties
of piston are the parameter used for this work. The analysis
shows that piston may be damaged or broken during the
operating conditions due to high temperature and structural
stress acting on the top surface of the piston. The main of aim
of this work is to study various researches done in past to
reduce the stress concentration on the head of the piston to
predict the higher stress and critical region on the component
by using FEM technique. The FEM performed by using ANSYS
simulation.
Key Words: IC Engine, Coating material, Piston, FEA
1.INTRODUCTION
Automobile components are in great demand and use of
automobiles is increased due to improved performance and
the cost of these components is reduced. The most used
drive of Motorcycles, primer movers, automobiles,shipsand
agricultural machines are still the internal-combustion,
piston engines. The piston has an important function of the
driving chain mechanism. It's main function is to lock one
side of the cylinder of the ic engine, to create the changing
volume, required for working. The thermal energy liberated
by the combustion of fuel, sparked with the ignition plugs
converts into mechanical energy as the piston moves in the
cylinder. The gas-energy takes effect on the surface of the
piston and makes it move on a straight line.
The energy liberated from the gas-pressure depends on the
diameter of the cylinder and thetoppressureofburningfuel.
This combustion process makes noise and quiver duringthe
engine works. During this combustion process, the piston is
subjected not just thermal energy but mechanically as well.
Top surface of the piston is touched directlywithhotgasand
the flame front. the piston is taxed by the thermal stress
which is heat transfer, and just partly heat radiation.
The temperature of the top surface of the piston is changing,
during the intake process it is the lowest, and during the
exhausting it is the biggest. Therefore, the thermal stress is
not constant. Because of high speed and at high loads on the
engine, the piston is subjected to high structural stress and
thermal stress. If these stresses exceed the designed values,
failure of piston may take place. Intensity of these stresses
should be reduced to have safe allowable limits. This review
introduces an analytical study and analysis of the thermal
effects and structural stresses on engine piston.
1.1 Piston Design
The piston is designed according to the procedure and
specification which are given in machine design and data
hand books. The dimensions are calculated in terms of SI
Units. The pressure applied on piston head, temperatures of
various areas of the piston, heat flow, stresses, strains,
length, diameter of piston and hole, thicknesses, etc.,
parameters are taken into consideration. [1]
1.2 Thermal Barrier Coating
In internal combustion engine, 55% energy is west in
coolant, exhaust and friction so only 45% of energy
converted into useful work. TBC is the advance coating
material technique which is appliedtothemetallicsurfaceto
operate at higher temperaturerangeandprovidesthehigher
thermal efficiency of the IC engine and reduced emission.
Ceramic have wear characteristic than other materials as
well as lower heat rejectionfromthecombustionchamberto
thermally insulated component.
2. LITREATURE REVIEW
1. Ch. Venkatarajam et al (2013) [1] have studied that the
efficiency is improve by reduced the weight of the piston.
The result showed that the total volume of the piston is
reduced by 24%, Vonmisses stress is increased by 16% and
deflection is increased but all the parameter is well with in
piston design consideration. TheFEAanalysiscarriedout for
ceramic coated diesel engine piston and the result indicate
that the maximum stress has changed from 63.019 MPa to
74.95 MPa.
2. Xiqun Lu et al (2013) [2] have studied the boundary
condition for numerical simulation is verified with
experiment result and applied to forecast the temperature
variation of a new piston outline which had minor change of
piston head design and one less ring scheme. Analytical

agreement wasobtained betweenpredictionandexperiment
for the new piston design. Experiment observation showed
increase of temperature in low temperature area and
decrease of maximum value in high-temperature area. The
thermal load of the top ring for new piston was lower than
old one. The new design had some potential of intensifying
improvement from the view point of piston thermal load.
3. Rahul D. Raut et al (2015) [3] have studied the design of
the piston development can reach to a massreductiononthe
base of stress analysis fulfill the condition of automobile
specifications with cost and size effectiveness. The
equivalent stress value considered for the new model iswell
below the range of value of 100 MPa. From new results it is
clear that there is a chance for reduction in the thickness of
piston skirt. The design of piston is done and it is found that
the mass of reduce piston is 0.2454 Kg. Hence percentage
reduction in mass compared tooldpiston(0.2574Kg)is4.66
%. The material is removed to reduce the weight of the
piston so as to improve the efficiency. It is needed to obtain
the new results for piston with reduced material. The factor
of safety becomes higher thanoldmodel i.e.design wasmore
preferable. The factor of safety after optimization is higher
result obtained.
4.M.Murugan et al (2012) [4] study design analysis for four
stroke petrol engine using commercial simulation tool
ANSYS.It is observed that factor of safety of the ALGHS1300
is higher than A2618 piston. After optimization mass of the
piston is 15% reduced and also inertia force is reduced 15%
that and maximize the engine performance.
5.Sathishkumar Sankar et al (2016) [5] illustrate design
procedure for four stroke petrol engine piston for hero
splendor pro bike and its analysis by its comparison with
original piston dimension used in bike. Using analytical
method, the design procedure of the piston involves
determinationofvariousdimensionsundermaximumpower
condition.The result showed that the use of analytical
method are nearly equal to the actual dimensions.
6. Deovrat Vibhandik et al (2014) [6] compare the behavior
of the combustion engine piston made of structural steel,
aluminium alloy and titanium alloy under thermal load. FEA
analysis is carried out to reduce the stress concentration on
the upper end of the piston by using commercial code,
namely ANSYS. The investigation shows that titanium has
better thermal properties but it is expensive and may be it is
uneconomical for large scale application.
7. Vinod Yadav et al (2013) [7] inferred that change in
material of the piston can be changed for the better strength
and light weight.
8.Muhammet Cerit (2011) [8] determine the temperature
and the stress variation in a partial ceramic coated spark
ignition (SI) engine piston. The outcome ofcoatingthickness
and width on temperature and stress variations were
determine consider comparisons with observation from an
uncoated piston. It is shows that the coating surface
temperature increase with increasing the thickness in a
decreasing rate. Surface temperature of the piston with 0.4
mm coating thickness was increased up to 82°C.The normal
stress on the coated surface decreases with coating
thickness, up to 1 mm for which the value of stress is the
minimum. However, it rises when coating thickness exceeds
1 mm. As for bond coat surface, increasingcoatingthickness,
the normal stress decreasessteadilyandthemaximumshear
stress rises in a decreasing rate. The optimum coating
thickness was found to be near 1 mm under the given
conditions.
Fig -1:Shear stress distribution with the coating thickness
substrate surface.[8]
The maximum stress is a function of coating thickness. Due
to the maximum normal stress,surfacecrack istakesplaceat
the middle of the bottom surface of the ceramic coating
width in radial direction. When the coating thickness rise
slowly, it moves to the inner edge of the coating. The other
maximum normal stress which effect spalling of the ceramic
top coat from the bond coat happen on the bond coat
interface. The von Misses stress decreases with increasing
coating thickness. The shear stress which causes small
cracks increases with the coating thickness increase and its
maximum level at the inner edge of the coated area at the
interface. Finally, it was determined that the preferable
coating thickness for the ceramic coating was below 1 mm.

Fig -2: Normal stress distribution with the coating
thickness substrate surface. [8]
9. Ekrem Buyukkaya et al (2008) [9] Functionally graded
coatings are coating systems used to improve performances
of high temperature parts in diesel engines. These coatings
include of a transition from the metallic bondlayertocermet
and from cermet to the ceramic layer. In this paper, thermal
effect of functional graded coatings on AlSi and steel piston
materials was determined by method of using a commercial
code, namely ANSYS. Thermal analyses were employed to
deposit metallic, cermet and ceramic powders such as
NiCrAl, NiCrAl+MgZrO3 and MgZrO3 on the substrate. The
numerical results of AlSi and steel pistons are compared
with each other. It was shown that the maximum surface
temperature of the functional graded coating AlSi alloy and
steel pistons was increased by 28% and 17%, respectively.
Fig. -3: The variation of temperature over theextendedbase
metal surface (including bowl length) of the steel piston
coated with FGM.
The temperature values of FGM coating piston surface are
lower than old thermal barrier coating at the same coating
thickness so the increase of the layer number reduces the
thickness of top coat and raises the thermal diffusivity, and
thus the heat insulation capability of the coating system
slowly decreases.
10 Ekrem Buyukkaya et al (2007) [10] initially, thermal
analyses were determined on a regular (uncoated) diesel
piston, made of aluminum silicon alloy and steel. Then,
thermal analyses were performed on pistons, coated with
MgO–ZrO2 material by means of using a commercial code,
namely ANSYS. Last, the observed of four different pistons
were compared with each other. The outcome of coatingson
the thermal characteristics of the pistons were determined.
It has showed that the maximum surface temperature of the
coated piston with material which has low thermal
conductivity is improved approximately 48% for the AlSi
alloy and 35% for the steel. The maximum surface
temperature of the base metal of the coating piston is 261 °C
for AlSi and 326 °C for steel. Structural behaviors of the
regular metal materials were varied negative with
temperature. By means of ceramic coating, strength and
deformation of the materials was give the better
performance. Maximum surface temperature of the steel
piston is higher near to 14% than the AlSi alloy one.
11. I. TaymazT, K. C¸ akVr, A. Mimaroglu et al (2005) [11]the
goal by reducing energy lost to the coolant during thepower
stroke of the cycle. Ceramic coatings had a desirable
outcome in the reduction of wear and abrasion failure in
reciprocating and rotary engines for transportation and
stationary power. As functional temperatures were pushed
higher to desirable efficiency in these engines, the
wear/abrasion problem becomes more challenging because
lubrication in the high temperature locations becomes
increasingly. Ceramic coatings also given applications as
thermal barriers to higher the efficiency of the engines, by
reducing energy loss and cooling conditions. The main
objective is to evaluate the effects of ceramic coating on
diesel engines effective efficiency at different engine loads
and speeds. Experiments were included with six cylinders,
directly injected, turbocharged, intercooled diesel engine.
initially, this engine was tested at different speed and load
conditions without coating. Then, combustion chamber
surfaces (cylinder head, valves and piston crown faces were
coated with ceramic materials. Ceramic layers were made of
CaZrO3 and MgZrO3, by using plasma-coating method onto
the base of the NiCrAl bond coat. The ceramic-coated
research engine was tested at the same conditions as theold
(without coating) engine. The observation showed a
reduction in heat loss to the coolant and an increase in
effective efficiency. High temperatures on the combustion
chamber wall surface due to insulation cause a drop in
volumetric efficiency although increased boost pressure
from the turbocharger can be used to overcome this
problem. Effective efficiency is not improved to the same
extent that heat rejection is reducedbycombustionchamber
insulation. Using insulation to reduce the heat loss to the
cooling system of the engine causes the cylinder walls to
become hotter and increases the effective efficiency.
12. Dániel Vaczkó (2016) [12] want to decrease the specific
fuel consumption but to keep the same performance. The
major part of the energy loss on combustion transferred to
its environment by thermal radiation rather powertrain. In
order to decrease the thermal waste in future vehicles we
need to use other materials like as ceramic. This has great
attributes of today’s commonly used aluminumalloys,butin
addition bad heat transfer ability.

Main specifications of the Al2O3 technical ceramics in terms
of the development: low density, high melting point, high
hardness, high abrasion resistance, high-temperature
strength, brittleness, hardly manufactural.
Fig-4: Aluminum and ceramics piston torque-time diagram
During the initial stage of the development, the use and
application of the ceramics piston seemed to be safely
according to the analytic. He met the condition and
manufacturing methods of the technical ceramicsduringthe
outline process. While He elaborated new methods, found
new simulation processes during the development process,
there were plenty of signs, which showed that the result of
this development is going to be positive. After completing
the first experimental ceramics piston, the testswere shown
that the preliminary calculations were successful. It can be
declared – based on the measurement results – that the
efficiency of the engine has become better with the same
adjustments. I wish to make more experiments – besidesthe
application of the ceramics piston – to optimize the
adjustment of the parameters of the engine, so it can be
finalized that how better the parameters of the ceramics
piston engine were with the best adjustments, than the
engine assembled with the aluminum piston also with the
best adjustments.
3. CONCLUSIONS
The numerical simulations clearly show that temperature
and thermal stress distribution are a function of coating
thickness. The maximum normal and shear stress
components occur in the bond coat. The results indicate that
thermal stress is related to coating thickness. As seen here,
thermal performance of the piston increases with increased
coating thickness. When stressvaluesobtainedfromFEAare
compared with the mechanical properties of the aluminum
alloy and zirconia material, it can be seen that calculated
stress values are lower than the allowable stress values of
the materials. The experimental results show that cold start
HC emission of partially coated engine significantly
decreases and also no degradation in engine torque is
observed. As a result of increase in temperature, a slight
amount of decrease in carbon monoxide emission may be
expected since CO oxidation reactions strongly depend on
temperature. SI engines work with rich mixtures and higher
cycle to cycle variations at cold idle operation. Using
insulation to reduce the heat loss to thecooling systemofthe
engine causes the cylinder walls to become hotter and
increases the effective efficiency. Effective efficiency is not
improved to the same extent that heat rejection is reduced
by combustion chamber insulation.
ACKNOWLEDGEMENT
I am very thankful to all those who helped me for the
successful completion of the literature review and for
providing valuable guidance throughout the Semester. I
would like to thank Asst. Prof. Maulik Modi, Dr. Tushar M
Patel and our Departmentof Mechanical Engineering,LDRP -
ITR, Gandhinagar. Their constant support, encouragement,
and constructive criticism have been invaluable assets
through my project work.
REFERENCES
[1] Ch.Venkata Rajam, P.V.K.Murthy, M.V.S.Murali Krishna,
G.M.Prasada Rao “Design Analysis and Optimization of
Piston using CATIA and ANSYS” January 2013, issue 2
volume 1International Journal ofInnovativeResearchin
Engineering & Science
[2] Xiqun Lu, Quan Li, Wenping Zhang, Yibin Guo, Tao He,
Dequan Zou “Thermal analysis on piston of marine
diesel engine” Applied Thermal Engineering 50 (2013)
168e176 19 June 2012 ELSEVIER
[3] Rahul D. Raut1, Satish Mishra ‘Stress Optimizationof S.I.
Engine Piston, International Journal of Science and
Research (IJSR), Volume 4 Issue 9, September 2015
[4] M.Murugan,T.Velmurugan,K.M.Parammasivam ”Design
Analysis and ParametricOptimizationof TwoAluminum
Piston Alloy Using SimulationTools”Journal ofChemical
and Pharmaceutical Sciences Vol. 9 ISSUE 4 December
2016
[5] Sathishkumar Sankar, Rajesh Kumar “Design and
Structural Analysis of IC Engine Piston Using FEA
Method Innovation Conference on Innovations and
Challenges in Engineering and Technology, Research
gate April 2016
[6] Deovrat Vibhandik, Ameya Pradhan, Sampada Mhaskar,
Nikita Sukthankar, Atul Dhale “Design Analysis and
Optimization of Piston andDeterminationofitsThermal
Stressesm Using CAE Tools” International Journal of
Engineering Sciences & ResearchTechnology[375-381]
may2014.

[7] Vinod Kumar Yadav, Yogesh Mishra “Design and
Structural Analysis of Ceramic Coated Petrol Engine
Piston Using Finite Element Method” International
Journal Innovative Research inScience,Engineeringand
Technology Vol. 4, Issue 6, June 2015
[8] Muhammet Cerit, “Thermo mechanical analysis of a
partially ceramic coated piston used in an SI engine”
Surface & Coatings Technology 205 (2011) 3499–3505,
ELSEVIER
[9] Ekrem Buyukkaya, “Thermal analysis of functionally
graded coating AlSi alloy and steel pistons” Surface &
Coatings Technology 202 (2008) 3856–3865,ElSEVIER.
[10] Ekrem Buyukkaya , Muhammet Cerit “Thermal analysis
of a ceramic coating diesel engine piston using3-Dfinite
element method” Surface & Coatings Technology 202
(2007) 398–402 ElSEVIER
[11] I. TaymazT, K. C¸ akVr, A. Mimaroglu “Experimental
study of effective efficiency in a ceramic coated diesel
engine” Surface & Coatings Technology 200 (2005)
1182– 1185 ElSEVIER
[12] Dániel Vaczkó “Piston development of a
microconsumption race car” International Conference
on Manufacturing EngineeringandMaterials,ICMEM,6-
10 June 2016, Nový Smokovec, Slovakia

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