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Effects of electrolytic jet plasma oxidation (EJPO) coatings on thermal behavior of engine cylinders

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Abstract

Aluminum engine blocks with ceramic-coated cylinder bores can effectively reduce the self-weight and largely improve the wear resistance. However, the presence of coatings to some extent also affects the heat transfer of internal combustion (IC) engine between the cylinder and the coolant due to their low thermal conductivities. In this paper, electrolytic jet plasma oxidation (EJPO) coatings were adopted to deposit on the engine cylinder bores. A three-dimensional transient finite element analysis (FEA) thermal model was developed to investigate the thermal behavior of EJPO-coated cylinders. It was found that both coating thickness and thermal conductivity could significantly influence the bore surface temperature and temperature fluctuation behaviors at the different crank angles. A possible selection of the parameter combination of coating thickness and thermal conductivity would provide a newly promising opportunity in the design of a high-quality coating for the cylinder bores to improve IC engine efficiency.

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Abbreviations

b :

Cylinder wall thickness, m

c :

Specific heat capacity, J/kg·K

F :

Geometric view factor

h :

Enthalpy, J = kg

k :

Thermal conductivity, W/m•K

l :

Length from BDC to the top surface of the piston, m

.l 1 :

Length from BDC and the top ring, m

l 2 :

Length from BDC and the second ring, m

L :

Cylinder length, m

\( {q}_{cond,c}^{\prime \prime } \) :

Heat flux in the tangential direction (adiabatic), W/m2

\( {q}_{cond,h}^{\prime \prime } \) :

heat flux from cylinder head, W/m2

\( {q}_{cond,r}^{\prime \prime } \) :

Heat flux from the top and second rings, W/m2

\( {q}_{cond,s}^{\prime \prime } \) :

Heat flux to the engine chamber skirt, W/m2

\( {q}_{conv, fc}^{\prime \prime } \) :

Forced convection heat flux from coolant, W/m2

\( {q}_{conv, fg}^{\prime \prime } \) :

Forced convection heat flux from air-fuel combustion, W/m2

\( {q}_{conv, fp}^{\prime \prime } \) :

Forced convection heat flux near the chamber skirt, W/m2

\( {q}_{rad}^{\prime \prime } \) :

Radiation heat flux from combustion gases, W/m2

R :

Cylinder bore radius, m S stroke length, m

t :

Time, s

T :

Temperature, K

T in-cy :

Instantaneous in-cylinder air-fuel temperature, K

T ini :

Engine block initial temperature, K

T w,g :

Cylinder wall surface temperature on air-fuel side, K

r, θ, z :

Cylindrical coordinates

ρ :

Density, kg/m3

σ:

Stefan-Boltzmann constant = 5.67 × 10−8 W/m2K4

ε 1 :

Emissivity of combustion gases

ε 2 :

Emissivity of cylinder bore surface

BDC :

Bottom dead center

CGI :

Compacted graphite iron

EJPO :

Electrolytic jet plasma oxidation

FEA :

Finite element analysis

IC :

Internal combustion

MMC :

Metal matrix composite

MSC :

Middle stroke center

PTWA :

Plasma transferred wire arc

PVD :

Physical vapor deposition

SiRPA :

Silica-reinforced porous anodized

TDC :

Top dead center

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Acknowledgements

The research was supported by a Collaborative Research Development Grant, Natural Sciences and Engineering Research Council of Canada.

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Authors and Affiliations

  1. Department of Mechanical, Automotive and Materials Engineering, University of Windsor, Windsor, Ontario, N9B 3P4, Canada

    Xinwei Shen & Xueyuan Nie

  2. Powertrain Engineering Research and Development Centre, Ford Motor Company, Windsor, Ontario, N9A 6X3, Canada

    Jimi Tjong

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  1. Xinwei Shen
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Correspondence to Xueyuan Nie.

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Shen, X., Nie, X. & Tjong, J. Effects of electrolytic jet plasma oxidation (EJPO) coatings on thermal behavior of engine cylinders. Heat Mass Transfer 55, 2503–2515 (2019). https://doi.org/10.1007/s00231-019-02600-6

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