Plasma electrolytic oxidation thermal barrier coating for reduced heat losses in IC engines

Hegab, Abdelrahman; Dahuwa, Kamal; Islam, Reza; Cairns, Alasdair; Khurana, Ankit; Shrestha, Suman; Francis, Robin J.

doi:10.1016/j.applthermaleng.2021.117316

Cited by 24 publications

(6 citation statements)

References 40 publications

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“…At 100% load condition, the results were found to increase the CO emissions compared to the different loads such as 0%, 25%, 50% and 75%. At 1% to 75% load, the CO emission was found to be lower because of improvements in combustion and because more oxygen molecules are contained in biodiesel [40]. At all load conditions, the flow rate of the air will be constant, but the fuel flow rate will vary as the load varies.…”

Section: Co Emissionsmentioning

confidence: 99%

Impact of a Thermal Barrier Coating in Low Heat Rejection Environment Area of a Diesel Engine

Kumar

Reddy

et al. 2022

Sustainability

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The most recent developments in Thermal Barrier Coating (TBC) relate to engine performance, manufacturing and other related challenges. TBC on the piston crown and valves to enhance engine characteristics while using diesel and Mahua Methyl Ester (MME) as a petroleum fuel has a great sustainable development. For this utility, a Direct Injection (DI) conventional diesel engine was renewed to an LHR engine by applying 0.5 mm thickness of 3Al2O3-2SiO2 (as TBC) onto the piston crown and valves. The MME is used in the LHR (Low Heat Rejection) engine. For examination, the fuel injector pressure is set at 200 bar. Compared to a standard DI diesel engine, the results demonstrate that the application of TBC boosts brake thermal efficiency to 13.65% at 25% load. The LHR engine’s SFC and BTE significantly improved at full load while using MME fuel. The lower temperature of exhaust gases is achieved by combining MME and diesel fuels with TBC. It was observed that both MME with and without TBC significantly reduced the smoke density. In addition, it was exposed that using MME fuel with TBC very slightly reduced carbon monoxide emissions under all loads. It was also shown that MME with TBC significantly reduced environmental hydrocarbon emissions at all loads.

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Section: Co Emissionsmentioning

confidence: 99%

Impact of a Thermal Barrier Coating in Low Heat Rejection Environment Area of a Diesel Engine

Kumar

Reddy

et al. 2022

Sustainability

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“…This unique Keronite PEO is a patented electrochemical surface treatment process for generating oxide coatings on Al alloys. 10 The PEO coating forms a complex ceramic layer of α/γ-Al 2 O 3 (alumina) that drastically improves the tribological (wear) properties, and acts as a thermal barrier 11 and a corrosion protection layer. Because it is an oxidised layer (rather than a deposited coating), it offers excellent adhesion to the substrate metal, 12 which makes the coating extremely robust and able to withstand the relatively high thermal expansion rates of the aluminium substrate.…”

Section: Introductionmentioning

confidence: 99%

Alloy selection for wear-resistant lightweight aluminium brake disc

Shrestha,

Francis,

Smith

2024

Surface Engineering

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Brake discs for the rear axle of a high-performance sports car have been manufactured in three different lightweight materials; AA6082, AA7075 and AA2024 aluminium alloys. These were subsequently coated with a Keronite plasma electrolytic oxidation (PEO) ceramic layer. Full-scale dynamometer tests have been conducted against a standard low-met brake pad using a modified AK master test at increasing levels of braking temperature until a physical limit is reached. Microstructural characterisation of coating and brake pad wear and tribo-layer have been studied using SEM and EDX. In addition, post-dynamometer-test friction discs have been exposed to salt fog testing. Dynamometer tests give confidence that PEO-coated aluminium brake discs are a viable technical solution for vehicle lightweighting. In particular, compelling performance with respect to good coefficient-of-friction (CoF), extremely high coating adhesion, minimal disc and pad wear, low disc run-out, good heat dissipation, and good corrosion resistance has been demonstrated for Mat A (AA6082) alloy discs. Despite higher room temperature strength, the resulting performances of Mat B (AA7075) and Mat C (AA2024) are poor at higher braking temperatures, resulting in excessive coating spallation and subsequent grain boundary attack followed by severe intergranular corrosion.

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“…Ti, Al, Mg) and allows for a relatively easy coating of complex shapes without any special pretreatment. Moreover, some of the properties which are desired for TES applications, such as favourable thermal conductivity, heat emissivity, or thermal diffusivity, can be tailored by the addition of various particles to the electrolyte and their incorporation in fabricated layers [17][18][19]. Nevertheless, despite the fact that PEO coatings possess extraordinary properties, there are also some difficulties in their utilisation, such as the porosity of thus produced layers and proper coverage of large areas.…”

Section: Introductionmentioning

confidence: 99%

Anticorrosive PEO coatings on metallic cast heat enhancers for thermal energy storage

Raźny,

Dmitruk,

Naplocha

2023

Surface Engineering

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The research aims to determine whether a protective oxide coating obtained by plasma electrolytic oxidation (PEO) will prevent unfavourable changes occurring on the surface of aluminium heat enhancers for thermal energy storage (TES) based on phase change materials (PCMs). For domestic purposes (short-term, solar energy), salt hydrates are widely utilised as PCMs. Their low thermal conductivity makes the application of metal enhancers necessary to improve heat transfer in the unit. Due to the chemically aggressive nature of MgCl 2 ·H 2 O, aluminium enhancers can be negatively affected during working cycles. PEO was proposed to overcome corrosion issues in the units. Cast samples, coated with PEO for a short time in KOH-Na 2 SiO 3 electrolyte, were subjected to a molten MgCl 2 ·H 2 O environment. Mass change and the surface were studied via SEM, EDS, and XRD measurements. A thin layer of aluminium oxide prevented castings from changes occurring on the surface of the enhancer.

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Plasma electrolytic oxidation thermal barrier coating for reduced heat losses in IC engines

Cited by 24 publications

References 40 publications

Impact of a Thermal Barrier Coating in Low Heat Rejection Environment Area of a Diesel Engine

Impact of a Thermal Barrier Coating in Low Heat Rejection Environment Area of a Diesel Engine

Alloy selection for wear-resistant lightweight aluminium brake disc

Anticorrosive PEO coatings on metallic cast heat enhancers for thermal energy storage

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