skip to main content
OSTI.GOV title logo U.S. Department of Energy
Office of Scientific and Technical Information

Title: Experimental investigation of the relationship between thermal barrier coating structured porosity and homogeneous charge compression ignition engine combustion

Journal Article · · International Journal of Engine Research
 [1];  [2];  [3]; ORCiD logo [1];  [4];  [4];  [5]
  1. Clemson Univ., Greenville, SC (United States)
  2. Clemson Univ., Greenville, SC (United States); Robert Bosch LLC., Detroit, MI (United States)
  3. Clemson Univ., Greenville, SC (United States); Auburn Univ., AL (United States)
  4. Univ. of Connecticut, Storrs, CT (United States)
  5. Lawrence Livermore National Lab. (LLNL), Livermore, CA (United States)
+ Show Author Affiliations

Heat transfer has a monumental influence on homogeneous charge compression ignition combustion. When a thermal barrier coating is applied to the combustion chamber, the insulating effect magnifies the wall temperature swing, decreasing heat transfer during combustion. This enables improvements in both thermal and combustion efficiency without the detrimental impacts of intake charge heating. Increasing the temperature swing requires coatings with lower thermal conductivity and heat capacity. An enticing avenue for simultaneously decreasing both thermal conductivity and capacity is to increase the porosity fraction. A proprietary solution precursor plasma spray process enables discrete organization of the porosity structure, called inter-pass boundaries, which in turn produces a step-reduction in thermal conductivity for a given porosity level. In this investigation, yttria-stabilized zirconia is used to create four different thermal barrier coatings to study the potential of structured porosity as means of improving the “temperature swing” behavior in a homogeneous charge compression ignition engine. The baseline coating is “dense YSZ,” applied using a standard air-plasma spray process. Furthermore, significant reductions of the thermal conductivity are achieved by utilizing the solution precursor plasma spray process to create inter-pass boundaries with a moderate overall porosity. Performance, efficiency, and emissions are compared against both a baseline configuration with a metal piston and an air-plasma spray “dense YSZ” coating. Experiments are carried out in a single-cylinder gasoline homogeneous charge compression ignition engine with exhaust re-induction. Experiments indicate that incorporating structured porosity into thermal barrier coatings produces tangible gains in combustion and thermal efficiencies. However, there is an upper limit to porosity levels acceptable for homogeneous charge compression ignition engine application because an elevated porosity fraction leads to excessive surface roughness and undesirable fuel interactions. Comparison of the coatings showed the best results with coating thickness of up to 150 µm. Thicker coatings led to slower surface temperature response and attenuated swing temperature magnitude.

Research Organization:
Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States); Lawrence Livermore National Lab. (LLNL), Livermore, CA (United States)
Sponsoring Organization:
USDOE Office of Science (SC), Basic Energy Sciences (BES). Chemical Sciences, Geosciences & Biosciences Division; USDOE National Nuclear Security Administration (NNSA)
Grant/Contract Number:
AC05-00OR22725; AC52-07NA27344
OSTI ID:
1550727
Alternate ID(s):
OSTI ID: 1809190
Report Number(s):
LLNL-JRNL-789757
Journal Information:
International Journal of Engine Research, Vol. 22, Issue 1; ISSN 1468-0874
Publisher:
SAGECopyright Statement
Country of Publication:
United States
Language:
English
Citation Metrics:
Cited by: 16 works
Citation information provided by
Web of Science

References (25)

An Assessment of the Performance and Requirements for "Adiabatic" Engines journal May 1988
Effect of Mirror-Finished Combustion Chamber on Heat Loss
  • Tsutsumi, Yasuhito; Nomura, Kenichi; Nakamura, Noriniko
  • International Fuels & Lubricants Meeting & Exposition, SAE Technical Paper Series https://doi.org/10.4271/902141
conference October 1990
Inverse Analysis of In-Cylinder Gas-Wall Boundary Conditions: Investigation of a Yttria-Stabilized Zirconia Thermal Barrier Coating for Homogeneous Charge Compression Ignition journal May 2017
Estimation of Thermal Barrier Coating Surface Temperature and Heat Flux Profiles in a Low Temperature Combustion Engine Using a Modified Sequential Function Specification Approach journal January 2017
Analysis of the effects of wall temperature swing on reciprocating internal combustion engine processes journal July 2017
Investigating the Development of Thermal Stratification from the Near-Wall Regions to the Bulk-Gas in an HCCI Engine with Planar Imaging Thermometry journal January 2012
The impact of a magnesium zirconate thermal barrier coating on homogeneous charge compression ignition operational variability and the formation of combustion chamber deposits journal November 2014
Hybrid Electric Vehicle Powertrain and Control Strategy Optimization to Maximize the Synergy with a Gasoline HCCI Engine journal April 2011
Concept of “Temperature Swing Heat Insulation” in Combustion Chamber Walls, and Appropriate Thermo-Physical Properties for Heat Insulation Coat journal April 2013
Assessment of Residual Mass Estimation Methods for Cylinder Pressure Heat Release Analysis of HCCI Engines With Negative Valve Overlap
  • Ortiz-Soto, Elliott A.; Vavra, Jiri; Babajimopoulos, Aristotelis
  • Journal of Engineering for Gas Turbines and Power, Vol. 134, Issue 8 https://doi.org/10.1115/1.4006701
journal June 2012
Predicting the gas-wall boundary conditions in a thermal barrier coated low temperature combustion engine using sub-coating temperature measurements journal January 2017
Thermal Barrier Coatings Made by the Solution Precursor Plasma Spray Process journal December 2007
Experimental Investigation on fuel film Formation by Spray Impingement on flat Walls with Different Surface Roughness journal January 2017
Characterizing the thermal sensitivity of a gasoline homogeneous charge compression ignition engine with measurements of instantaneous wall temperature and heat flux journal August 2005
Low-thermal-conductivity plasma-sprayed thermal barrier coatings with engineered microstructures journal July 2006
The Solution Precursor Plasma Spray (SPPS) Process: A Review with Energy Considerations journal July 2015
Impact of a Yttria-Stabilized Zirconia Thermal Barrier Coating on HCCI Engine Combustion, Emissions, and Efficiency journal August 2017
Superior thermal barrier coatings using solution precursor plasma spray journal March 2004
Reduction of Heat Loss and Improvement of Thermal Efficiency by Application of “Temperature Swing” Insulation to Direct-Injection Diesel Engines journal April 2016
PLIF Measurements of Thermal Stratification in an HCCI Engine under Fired Operation journal April 2011
Deposition mechanisms of thermal barrier coatings in the solution precursor plasma spray process journal January 2004
Fuel Storage in Com bustion-Chamber Ceramics and Hydrocarbon Emissions: A Connection journal February 1987
Highly durable thermal barrier coatings made by the solution precursor plasma spray process journal January 2004
Low Thermal Conductivity Yttria-Stabilized Zirconia Thermal Barrier Coatings Using the Solution Precursor Plasma Spray Process journal February 2014
Impact of a Yttria-Stabilized Zirconia Thermal Barrier Coating on HCCI Engine Combustion, Emissions, and Efficiency conference December 2016

Figures / Tables (32)

Figure 1(p. 3)figure Figure 1
Figure 2(p. 4)figure Figure 2
Figure 3(p. 5)figure Figure 3
Figure 4(p. 7)figure Figure 4
Figure 5(p. 8)figure Figure 5
Figure 6(p. 9)figure Figure 6
Figure 7(p. 10)figure Figure 7
Table 1(p. 10)table Table 1
Figure 8(p. 11)figure Figure 8
Figure 9(p. 12)figure Figure 9
Table 3(p. 13)table Table 3
Figure 10(p. 14)figure Figure 10
Figure 11(p. 17)figure Figure 11
Table 2(p. 17)table Table 2
Figure 12(p. 18)figure Figure 12
Figure 13(p. 19)figure Figure 13
Figure 14(p. 20)figure Figure 14
Figure 15(p. 21)figure Figure 15
Figure 16(p. 22)figure Figure 16
Figure 17(p. 22)figure Figure 17
Figure 18(p. 23)figure Figure 18
Figure 19(p. 24)figure Figure 19
Figure 20(p. 25)figure Figure 20
Figure 21(p. 25)figure Figure 21
Figure 22(p. 27)figure Figure 22
Figure 23(p. 28)figure Figure 23
Figure 24(p. 29)figure Figure 24
Figure 25(p. 29)figure Figure 25
Figure 26(p. 30)figure Figure 26
Figure 27(p. 31)figure Figure 27
Figure 28(p. 32)figure Figure 28
Figure 29(p. 33)figure Figure 29

Similar Records

Enhancing the efficiency benefit of thermal barrier coatings for homogeneous charge compression ignition engines through application of a low-k oxide
Journal Article · Mon Jun 01 00:00:00 EDT 2020 · International Journal of Engine Research · OSTI ID:1550727
+3 more
Experimental Investigation of Low Cost, Low Thermal Conductivity Thermal Barrier Coating on HCCI Combustion, Efficiency, and Emissions
Journal Article · Tue Apr 14 00:00:00 EDT 2020 · Society of Automotive Engineers Technical Paper Series · OSTI ID:1550727
+3 more
Low Thermal Conductivity, High Durability Thermal Barrier Coatings for IGCC Environments
Technical Report · Thu Jan 15 00:00:00 EST 2015 · OSTI ID:1550727

Related Subjects

33 ADVANCED PROPULSION SYSTEMS
Thermal barrier coating
yttria-stabilized zirconia
low temperature combustion
heat transfer
homogeneous charge compression ignition