The effects on heat transfer of piston crown surface finish and use of a metal based thermal barrier coating (TBC) on the piston crown were studied in an SI engine. Measured engine parameters such as power, fuel consumption, emissions and cylinder pressure were used to identify the effects of the coating and its surface finish. Two piston coatings were tested: a baseline copper coating and a metal TBC. Reducing surface roughness of both coatings increased in-cylinder temperature and pressure as a result of reduced heat transfer through the piston crown. These increases resulted in small improvements in both power and fuel consumption, while also having measurable effect on emissions. Oxides of nitrogen emissions were increased while total hydrocarbon emissions were decreased. Improvements attributed to the TBC were found to be small, but statistically significant. At an equivalent surface finish, the TBC performed better than the baseline copper finish.iii

The engine was operated in a standard full load mode and a knock promoting mode featuring heated intake air and advanced spark timing. Cylinder pressures were measured to quantify knock.It was found that average heat flux into the piston substrate was 33 % higher with the metal TBC and unchanged with the YSZ relative to the uncoated surface. The increase with the metal TBC was attributed to its surface roughness. However, the metal TBC and YSZ reduced peak heat flux by 69 and 77 %, respectively. Both the metal TBC and YSZ reduced knock compared to the uncoated surface. After testing, the metal TBC was undamaged and the YSZ was slightly chipped.ii DedicationTo my late grandpa Joseph.iii