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Evaluation of Mechanical, Tribological, and Thermal Characterization of GZ TBCs for Heavy Duty Diesel Engine Application

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Abstract

Environmental regulations governing heavy-duty diesel engines (HDDE) have become more stringent, mandating them to ensure a lower environmental and human health impact, with improved efficiency in terms of emissions and fuel economy. The focus of most of the researches is on advancement in thermodynamic cycles and maximum heat utilization techniques. Thermal barrier coating (TBCs) is one of the most efficient methods of increasing energy efficiency through effective utilization of heat by insulating the turbine and combustor engine components. The primary focus of this work, is on the effective material behaviour of TBCs on HDDE components in terms of mechanical, tribological and thermal characterization. Inlet and exhaust valve substrates were coated with Gadolinium Zirconate (GZ) with and without bond coat (NiCr) with a thickness of 100 and 150 µm respectively using the plasma spray technique. Reciprocative wear, thermal conductivity and expansion behavior of uncoated and coated substrates were carried out as per the ASTM Standards. The results indicated a reduction in co-efficient of friction in GZ/NiCr substrate by 15 and 3% in comparison with uncoated and GZ coated substrate respectively. Furthermore, the mean expansion value of GZ/NiCr substrate was 10.04% lower than the GZ coated substrate, substantiating the reduction in micro-crack formation as a result of combating the CTE mismatch between substrate and coating. Among the samples, GZ/NiCr substrate showed a maximum reduction in thermal conductivity accounting to 8 to 11%. These findings elaborate the capability of TBCs towards improving wear resistance and sustaining high temperature thermal exposure of combustion chamber components in HDDE.

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Acknowledgments

The author would like to express his sincere thanks to Scientists Dr. Dhanalakshmi Sathiskumar, Dr. Vishwanathan, Mr. Kumaraswamy, and Mr. Vamsi Krishna from CVRDE-DRDO, Avadi, Chennai, Tamilnadu for supporting the overall research activities. The authors would also like to thank Dr. Natarajan Venkat, Ex-Director and Scientist ‘G’, RIC-DRDO for providing the permission to utilize Multi-Functional Tribometer (MFT-5000, USA) and also Mr. Naveen Kumar for helping to carry out the tribology test. Further, I thank Dr. G Sakthinathan and Dr. R Vignesh for their expertise and assistance in analyzing the characterization study of ceramic coated substrates.

Funding

This research was supported by the Defence Research and Development Organization (DRDO).—Combat Vehicles Research and Development Establishment (CVRDe), India and Research Innovation Centre (RIC), IITM Research Park, Chennai [Grant No: ERIP/ER/201807001/M/01/1746].

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  1. Department of Manufacturing Engineering, Anna University, CEG Campus, Chennai, 600025, India

    Raja Velusamy, A. Suresh Babu & P. Hariharan

  2. Department of Mechanical Engineering, Anna University, CEG Campus, Chennai, 600025, India

    M. R. Swaminathan

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Velusamy, R., Babu, A.S., Swaminathan, M.R. et al. Evaluation of Mechanical, Tribological, and Thermal Characterization of GZ TBCs for Heavy Duty Diesel Engine Application. J. of Materi Eng and Perform 33, 2736–2750 (2024). https://doi.org/10.1007/s11665-023-08164-1

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