IMPROVING EFFICIENCY AND FUEL

CONSUMPTION OF ENGINE BY
THERMAL BARRIER COATING WITH
JATROPHA BLEND
Presented by :

P SURESHKUMAR 14KA1A0309
P RAJESHKUMAR 14KA1A0305
T HARITHA 14KA1A0307
U SRINIVASA RAO 14KA1A0312

UNDER THE GUIDANCE OF

P.RATNARAJU M.Tech
 CONTENT
 Introduction.
 ConstructionAnd Working.
 Material Selection.
 TBC Coating for Ic Engines.
 Material used for TBC in ic engine.
 TBC Deposition Methods.
 Properties of Jatropha
 Function of jatropha
 INTRODUCTION
 TBCs are refractory oxide ceramic coatings applied to the surfaces
of hot metallic parts.

 TBCs perform the important function of insulating components

operating at elevated temperature.

 Coatings can allow higher operating temperatures beyond the

limiting temperature of metal parts.

 TBC not only consist of oxide ceramic coating (topcoat) itself but
also the underlying superalloy engine part, and two other layers in
between.
CONSTRUCTION AND WORKING
 Metallic Bond Coat with a thickness of about 0.004” (0.1 mm). The
alloy of the bond coating is MCrAlY, where M is Ni, Fe or Co.e bond
coat is an intermediate layer providing strong adhesion of the outer
ceramic layer to the substrate surface.
 The bond coat also inhibits the diffusion of the substrate and the ceramic
coating components. Aluminum in the amount of about 10% in the bond
coat is required for a formation of an oxide barrier (thermally grown
oxide) on the interface between the bond coatand the ceramic layer. The
thermally grown oxide form as a result of oxidation of the bond coat with
Oxygendiffusing from the combustion gases throghout the ceramic layer.
The oxide laye riscomposed of α-Al2O3.

 Outer ceramic layer (Top Coat) Commonly 30%

Molybdenum And 40% aluminium oxide and 30% titanium oxide with
tetragonal crystal structure is used for building the outer ceramic layer.
 Material Selection for TBC

 Material selected for TBC should have following properties:-

 Low Thermal Conductivity.

 High Thermal Expansion Coefficient.

 Good Erosion Resistance.

 Materials used for thermal barier
coating
in ( IC ENGINE ).
 Molybdenum.
 Zirconates.
 Yittria Stabilized Zirconia.
 Mullite.
 Alumina.
 Spinel.
 Forsterite.
TBC coating for ic engines and coating
methods
 Thermal barrier coatings are used in order to increase reliability and
strength of hot parts of metal components, increase yield and
performance of engines.

 Engine parts which are coated with thermal barrier are piston,
cylinder head cylinder sleeve and exhaust valves.

 1. Electron Beam Physical Vapour Deposition (EBPVD).

 2. Air Plasma Spray (APS).
 3. Electrostatic Spray Assisted Vapours Deposition (ESAVD).
 4. Direct Vapour Deposition.
 5. ELECTRON BEAM PHYSICAL VAPOR DEPOSITION.
 Air Plasma Spray.

 In plasma spraying process, the material to be deposited (feedstock) is

introduced into the plasma jet, emanating from a plasma torch.
 In the jet, where the temperature is of the order of 10,000 K, the
material is melted and propelled towards a substrate.
 There, the molten droplets flatten, rapidly solidify and form a deposit.
 Advantages.
 There is a wide range of coating materials that meet a wide variety of
different needs, with nearly all materials available in a suitable powder form.
 Higher quality coatings such as flame or electrical arc spraying.
 Many types of substrate material, including metals, ceramics, plastics, glass,
and
composite materials can be coated using plasma spraying.

Disadvantages.
 Air plasma spraying equipment is generally very expensive to buy and use.
 It is a line-of-sight process, similar to all other thermal spraying processes, making
it difficult to coat internal bores of small diameters or restricted access surfaces.
Electron-beam physical vapor deposition
(EB-PVD).

 Electron Beam Physical Vapour Deposition or EBPVD is a form of

physical vapour deposition in which a target anode is bombarded
with an electron beam which causes atoms from the target to
transform into the gaseous phase.
 These atoms then precipitate into solid form, coating everything in
the vacuum chamber (within line of sight) with a thin layer of the
anode material.
ADVANTAGES.
 The material utilization efficiency is high relative to other methods.
 This process has potential industrial application for wear -resistant and TBC in
aerospace industries.
 Due to the very high deposition rate.

Disadvantages.
 This process cannot be used to coat the inner surface.
 Performed at a low enough pressure.
 TBC MATERIAL
 A Ni-Al-Mo self bonding composite one step powder.
 Exhibits good wear resistance for hard bearing applications .
 Has extremely high bond strength making it an ideal material for spraying inside
diameters.

 Can be finished with carbide tools.

 Takes heavy build ups without cracking due to high interparticle bonding.
 Extremely good material for inside bearing fits.
 Molybdenum properties
Molybdenum properties
Atomic number 42
Atomic weight 95.96
Crystal structure Body-centered cubic (BCC)

Lattice constant a= 3.1470 A⁰

Density 10.22 g/cm^3
Melting Temperature 2623⁰C
Coefficent of Thermal 4.8 ×10^-6 /K AT 25⁰C
expansion
Thermal conductivity 138 W/m K at 20⁰C
 PROPERTIES OF JATROPHA

PROPERTTIES JATROPHA OIL

 Density(gm/cc) 0.93292

 Kinematic viscosity(cm^2/sec) 52.76

 Cetane no. 38.00

 Flash point(temp) 210.00

 Calorific value(MJ/Kg) 38.20

 Saponification value 198.00

 Iodine no. 94.00

 FUNCTION OF JATROPHA BLEND

 Jatropa curacus biodeisel blends were evaluted as antioxidants

 The use of antioxidants provided good stabilization along with a slightly lower bsfc

 Antioidants –added blends reduced nox emisson.

 Addition of antioxidants increased their oxidation stability with out causing any
negative effeect on other physicochemical properties.

 Addition of antioxidants increased bp and reduced bsfc .

 EXPERIMENTAL SECTION

• A four stroke, direct injected, water cooled single cylinder diesel engine
was used for experimental work. The Engine tests conducted with
variable loads at a constant engine speed were directly coupled with
eddy current dynamometer.
• The combustion chamber insulation with 300µm thickness is applied
on the piston crown using atmospheric plasma spraying coating with
different composition such as Aluminium oxide (Al2O3) +
Molybdenum (Mo) + Titanium oxide (TiO2) (40%+30%+30%).
• Over a thickness of Ni-Cr bond coat. The thermal barrier coated piston
engine was compared with the standard engine.
 OBSERVED DATA OF STANDARD DIESEL WITH OUT
COATED PISTON
TIME INDICATE

TAKE BRAKE D

N FOR THERMA THERMA MECHAN

10CC L L ICAL
LOAD SPEED (SEC) TORQUE IMEP BMEP TFC BSFC EFFICIEN EFFICIEN EFFICIEN
(kg) (rpm) (Nm) IP (kw) BP (kw) (bar) (bar) (kg/hr) (kg/kwh) CY (%) CY (%) CY (%)

0 1500 86.4 0 2.8 0 3.39 0 0.35 - 0 67.76 0

4.5 1500 50.4 8.16 4.083 1.283 4.94 1.55 0.6 0.467 18.11 57.64 31.4

9 1500 37.3 16.33 5.365 2.565 6.50 3.10 0.81 0.315 26.8 56.10 47.8

13.5 1500 29.94 24.5 6.649 3.849 8.05 4.65 1.01 0.262 32.28 55.763 57.8
 OBSERVED DATA OF COATED PISTON WITH
DIESEL

INDICATE
TIME
BRAKE D
TAKE
THERMA THERMA MECHAN
N FOR
L L ICAL
10CC
LOAD SPEED TORQUE IMEP BMEP TFC BSFC EFFICIEN EFFICIEN EFFICIEN
(SEC)
(kg) (rpm) (Nm) IP (kw) BP (kw) (K.Pa) (K.Pa) (kg/hr) (kg/kwh) CY (%) CY (%) CY (%)

0
1500 79.57 0 2.7 0 326.56 0 0.38 - 0 60.1 0

4.5 1500 47.25 8.16 3.98 1.28 481.74 155.17 0.64 0.49 16.9 52.71 32.2

9 1500 35.16 16.33 5.26 2.56 636.8 301.02 0.86 0.33 25.26 51.85 48.7

13.5 1500 28.26 24.5 6.54 3.84 792.1 465.4 1.07 0.28 30.47 51.84 58.77

18 1500 23.44 32.67 7.83 5.13 947.03 620.5 1.27 0.25 33.68 51.41 65.5
 OBSERVED DATA WITH JATROPHA BLEND
(B20)
INDICATE
TIME BRAKE D
TAKE THERMA THERMA MECHAN
N FOR L L ICAL
LOAD SPEED 10CC TORQUE IMEP BMEP TFC BSFC EFFICIEN EFFICIEN EFFICIEN
(kg) (rpm) (SEC) (Nm) IP (kw) BP (kw) (K.Pa) (K.Pa) (kg/hr) (kg/kwh) CY (%) CY (%) CY (%)

0 1500 60 0 2.4 0 293.3 0 0.55 - 0 39.76 0

4.5 1500 39.78 8.16 3.6 1.28 445.8 155.1 0.81 0.18 14.4 41.4 348

9 1500 30.39 16.33 4.9 2.56 600 310.2 1.06 0.11 22 42.6 51.6

13.5 1500 25.57 24.5 6.2 3.84 755.8 465.4 1.26 0.09 27.8 45.2 61.5

18 1500 20.65 32.67 7.5 5.13 901.7 620.4 1.56 0.08 30 43.9 68.1
 ANALYSIS
• Increasing temperature level in the combustion chamber
decreased the ignition delay and decreased the fuel burnt during
the pre-mixed combustion phase.
• There will be an increase in NOxemission with increase in
temperature .
• For reducing NOx, jatropha biodiesel blend is used .
• Molybdenum in the top surface of the piston reduces the crack
formation due to high heat directly applied on the surface,
resulting in increasing thermal expansion co-efficient and
important thermal properties of piston .