Potential use of quasicrystalline materials as thermal barrier coatings for diesel engine components

Beardsley, Megan

doi:10.31274/rtd-180813-16873

Cited by 5 publications

(3 citation statements)

References 60 publications

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“…The structural integrity of thermal barrier coatings has been a challenge that has limited their widespread adoption in engines, and reports of failures are prevalent in the literature. [44][45][46][47][48][49][50] Rapid heating and cooling of the surface leads to coating delamination (debonding). Optimizing solely for heat transfer may result in impractical coating materials and thicknesses.…”

Section: Introductionmentioning

confidence: 99%

Optimization of thermal barrier coating performance and durability over a drive cycle

Koutsakis

Ghandhi

2022

International Journal of Engine Research

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A methodology to thermo-mechanically optimize a piston thermal barrier coating over a full drive cycle was established. The optimization objective was to minimize the heat transfer to the engine wall while maintaining structural integrity of the coating. Over 800 candidate materials were investigated and the optimization required more than one million non-road transient drive cycle calculations; real materials were investigated to ensure a realizable result and the existence of thermal and mechanical properties. High computational efficiency was achieved using a recently developed analytical heat transfer technique for multilayer engine walls. An uncoupled approach was utilized for the optimization, wherein the gas temperature and heat transfer coefficient profiles from a fully coupled and calibrated baseline model over the 20-min drive cycle were employed. The coating/piston interface temperature was constrained to be below the maximum piston service temperature limit. The durability was assessed using a recently developed analytical coating delamination framework for engine in-cylinder coatings based on the energy release rate when a crack forms. Results are presented for a mechanically unconstrained optimization and for cases constrained to three fixed levels of drive-cycle maximum energy release rate, and also constrained by the individual material’s toughness. The best-performing coating materials identified were verified using the fully coupled system-level model, which compared well to the uncoupled predictions. A study on the effect of adding a sealing layer to some high-performing, but porous, coatings showed a reduction in fuel consumption benefit and an increased exhaust temperature over the cycle, but the system still outperformed the uncoated case. The results of the study elucidate the importance of including engine performance and mechanical failure considerations in thermal barrier coating design.

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Section: Introductionmentioning

confidence: 99%

Optimization of thermal barrier coating performance and durability over a drive cycle

Koutsakis

Ghandhi

2022

International Journal of Engine Research

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“…Multilayered quasicrystal (QC) composites possess huge potential applications in the aeronautical and aerospace industries, manufacturing of semiconductor and electrical devices as well as some modern high-technology sectors due to their unique quasiperiodic structure and excellent physical properties (Fan, 2011;Guo et al, 2020). In addition, due to the high hardness, good chemical stability, high temperature resistance, and corrosion resistance of QC materials, QC coating technology has been tremendously developed (Beardsley, 2008;Mora et al, 2020), which proposed new ways to improve the aeroengine performance. Compared with monolithic samples, artificially designed layered QC coating structures can provide better combinations of strength and ductility, strength-to-weight ratios, and stiffness-to-weight ratios.…”

Section: Introductionmentioning

confidence: 99%

Forced vibration analysis of inhomogeneous quasicrystal coating in a thermal environment

et al. 2022

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The tremendous attention of researchers has been attracted to the unusual properties of quasicrystals in coatings. In this paper, the exact solutions of the functionally graded multilayered two-dimensional quasicrystal coating structures in a thermal environment are derived for advanced boundary-value problems with mixed boundary conditions. The state space method is formulated to the thermal coupling with quasicrystal linear elastic theory that derives the state equations for functionally graded quasicrystal coating structures along the thickness direction. The mixed supported boundary conditions in the x-direction and the simply supported boundary conditions in the y-direction are subjected to time-harmonic temperature loadings, which are represented by means of the differential quadrature technique and Fourier series expansions, respectively. Traction on both the bottom and top surfaces is free, and perfect thermal and mechanical contacts between constituents are incorporated at the internal interfaces. A global propagator matrix, which connects the field variables at the top interface to those at the bottom interface for the whole coating structure, is further completed by joint coupling matrices to overcome the numerical instabilities. Finally, three application examples are proposed to throw light on various effects of the power law index, frequency, and different boundary conditions on the field variables in three-layer coating structures. The present solution can serve as a benchmark for the modeling of functionally graded quasicrystal coating structures based on various numerical methods.

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“…Synthesis of such phases requires higher cooling and crystallization rates as compared to those for conventional processes. Some QCs have extremely low thermal conductivity, which makes it possible to use coatings made of them as thermal barriers in elements of various engines [20]. It is notable that QCs possess thermal expansion coefficient values close to that of structural metal, bringing increased resistance to thermal cycling.…”

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confidence: 99%

Prospects for the Implementation of New Materials and Technologies in the Aerospace Industry

Yanko

Dmytrenko

2021

Transactions on Aerospace Research

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This article considers the main materials used to make aircraft, both fuselage and engines. First, the problems that force developers to introduce new materials in aircraft production are identified. We then present features of the introduction of heat-resistant titanium alloys, ways of improving the mechanical properties of parts made of titanium alloys, and methods of manufacturing complex details. Other promising materials for the aviation industry, such as high-entropy alloys, quasicrystals, carbon-carbon materials, and nickel foam, are also considered.

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Potential use of quasicrystalline materials as thermal barrier coatings for diesel engine components

Cited by 5 publications

References 60 publications

Optimization of thermal barrier coating performance and durability over a drive cycle

Optimization of thermal barrier coating performance and durability over a drive cycle

Forced vibration analysis of inhomogeneous quasicrystal coating in a thermal environment

Prospects for the Implementation of New Materials and Technologies in the Aerospace Industry

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