Thermomechanical performance and durability analysis of graded thermal barrier coatings over engine piston using finite element analysis

Current work aims at analysis of Graded thermal barrier coated piston assembly subjected to various thermomechanical loads during the power stroke. The piston is a key component of internal combustion engine which delivers the energy created by combustion to the crankshaft in the form of mechanical work. Piston is subjected to high temperature gases leading to the generation of stresses in the piston assembly. Functionally graded materials have gained importance as thermal barrier coatings due to their improved thermal performance and better adhesion due to their tailored mechanical, thermal and chemical properties.Initially four different functionally graded thermal barrier coatings (MgZrO3-iCrAl\documentclass[12pt]{minimal} \usepackage{amsmath} \usepackage{wasysym} \usepackage{amsfonts} \usepackage{amssymb} \usepackage{amsbsy} \usepackage{mathrsfs} \usepackage{upgreek} \setlength{\oddsidemargin}{-69pt} \begin{document}$$MgZrO_{3} - iCrAl$$\end{document},YSZ-NiCoCrAlY\documentclass[12pt]{minimal} \usepackage{amsmath} \usepackage{wasysym} \usepackage{amsfonts} \usepackage{amssymb} \usepackage{amsbsy} \usepackage{mathrsfs} \usepackage{upgreek} \setlength{\oddsidemargin}{-69pt} \begin{document}$$YSZ - NiCoCrAlY$$\end{document}, YSZ-NiCrAlY\documentclass[12pt]{minimal} \usepackage{amsmath} \usepackage{wasysym} \usepackage{amsfonts} \usepackage{amssymb} \usepackage{amsbsy} \usepackage{mathrsfs} \usepackage{upgreek} \setlength{\oddsidemargin}{-69pt} \begin{document}$$YSZ - NiCrAlY$$\end{document}, La2Zr2O7-iCoCrAlY\documentclass[12pt]{minimal} \usepackage{amsmath} \usepackage{wasysym} \usepackage{amsfonts} \usepackage{amssymb} \usepackage{amsbsy} \usepackage{mathrsfs} \usepackage{upgreek} \setlength{\oddsidemargin}{-69pt} \begin{document}$${ }La_{2} Zr_{2} O_{7} - iCoCrAlY$$\end{document}) have been simulated and compared using static thermal analysis. It was observed that MgZrO3-NiCrAl\documentclass[12pt]{minimal} \usepackage{amsmath} \usepackage{wasysym} \usepackage{amsfonts} \usepackage{amssymb} \usepackage{amsbsy} \usepackage{mathrsfs} \usepackage{upgreek} \setlength{\oddsidemargin}{-69pt} \begin{document}$$MgZrO_{3} - NiCrAl$$\end{document} coated piston reduced the Piston crown temperature by nearly 21.7% in comparison to uncoated piston.Selected FGM coating (MgZrO3-NiCrAl\documentclass[12pt]{minimal} \usepackage{amsmath} \usepackage{wasysym} \usepackage{amsfonts} \usepackage{amssymb} \usepackage{amsbsy} \usepackage{mathrsfs} \usepackage{upgreek} \setlength{\oddsidemargin}{-69pt} \begin{document}$$MgZrO_{3} - NiCrAl$$\end{document}) have been further tested under Transient thermo-mechanical analysis subjected to thermomechanical load in the power stroke. FGM coated piston assembly observed less heat flux in comparito uncoated piston assembly. It was observed that the MgZrO3-NiCrAl\documentclass[12pt]{minimal} \usepackage{amsmath} \usepackage{wasysym} \usepackage{amsfonts} \usepackage{amssymb} \usepackage{amsbsy} \usepackage{mathrsfs} \usepackage{upgreek} \setlength{\oddsidemargin}{-69pt} \begin{document}$$MgZrO_{3} - NiCrAl$$\end{document}. Graded piston aembly have 36.3% higher temperature than the uncoated piston assembly and Heat flux is reduces by 37.36% for FGM coated piston assembly in compared with coated piston assembly. These results shows the reduction of the transfer of high temperature gases to the Al-Si piston crown. The maximum von-misses stresses for FGM coated piston assembly was reduces by 28% in comparison to uncoated piston assembly. The maximum von-misses strains for FGM coated piston assembly was reduces by 24. 8% in comparison to uncoated piston assembly. Also MgZrO3-NiCrAl\documentclass[12pt]{minimal} \usepackage{amsmath} \usepackage{wasysym} \usepackage{amsfonts} \usepackage{amssymb} \usepackage{amsbsy} \usepackage{mathrsfs} \usepackage{upgreek} \setlength{\oddsidemargin}{-69pt} \begin{document}$$MgZrO_{3} - NiCrAl$$\end{document} graded piston assembly showed ls normal and shear stresses and strains in comparison to uncoated piston thereby enhancing the performance and durability of the piston assembly. Findings of this work shows that the FGM coatings over the piston helps to decreases the transfer high temperature over the Al-Si piston crown.