Temperature and Thermal Stress Analysis of TBC Coated Diesel Engine Piston for Variable Thickness of TBC

Abstract

The study investigated the thermal behavior of a coated as well as uncoated piston with finite element method using commercial software package Ansys. First, the temperature analysis of a piston which is made of aluminum alloy is carried out without a top coating. Next, the behavior of a top coat surface of Yttria-stabilized Zirconia (YSZ) is analyzed at varying thickness. We then investigated the distribution of temperature, and thermal stress on a top surface of the piston, bond coat, and substrate of piston. In the end, the results of various coating thickness are compared. It is noted that the temperature distribution was dependent upon coating thickness and the highest temperature appeared at the center of the top surface of the coated region and this temperature is higher than the top surface of uncoated piston. We noticed a decrease in piston substrate temperature as the coating thickness increases. When thickness of coating increased from 0.4 to 0.8 to 1.2 and 1.6 mm, it is observed that the maximum surface temperature of the coating increased by 19.26%, 33.70%, 45.48%, and 55.24%, respectively. © 2023, The Author(s), under exclusive license to Springer Nature Singapore Pte Ltd.