A parametric modeling study of thermal barrier coatings in low-temperature combustion engines

Abstract

• Low-temperature combustions are more favorable with the thick coating configurations. • In-cylinder thick thermal barrier coating improves the indicated thermal efficiency by 4.6%. • Thick thermal barrier coating increases the volumetric efficiency due to the lower IVC temperature. • Thick thermal barrier coating increases the exhaust enthalpy and reduces intake temperature requirement. In-cylinder thermal barrier coatings (TBCs) reduce heat transfer losses and increase thermal efficiency. It has been shown that thick TBCs negatively impact the performance of conventional combustion modes by degrading volumetric efficiency and increasing the propensity for end-gas knock. Low-temperature combustion (LTC) is an advanced combustion strategy that offers high efficiencies and low emissions. Due to the nature of kinetics-driven autoignition, LTC is fundamentally different from the conventional combustion modes, where the benefits and tradeoffs of thick TBCs need to be re-evaluated. Previous experimental studies showed the feasibility and the efficiency gains associated with a 2 mm thick TBC applied to the piston surface, as well as the reduction in the required intake temperature with no observable deterioration on the high load limit. However, the effects of TBCs and their independent thermophysical properties on LTC have not been systematically explored. It is necessary to perform a comprehensive study on the effects of TBC on LTCs from a fundamental thermodynamic perspective, which serves as the motivation for the current study. This study couples a 0D engine thermodynamic model to a 1D transient heat transfer model of the coating and piston. The model was first validated against the metal piston baseline, followed by validation against experimental data of the TBC cases at different engine loads. With confidence established in the model’s fidelity, three parameters are investigated independently: thermal conductivity ( k ), coating thickness, and volumetric heat capacity ( s ). The results revealed that the volumetric efficiency actually increases by 7.4 percentage points with a thicker coating due to a reduction in heat transfer during the compression stroke, which allows for a lower intake temperature requirement to reach autoignition. However, there is a thickness limit before the intake temperature becomes impractically low. The results show that elevating surface temperature is directly proportional to higher efficiency. Therefore, the optimal coating configuration for kinetically-controlled LTC is a combination of the lowest k , thickest coating before reaching the limit, and the lowest s , where the low k and high thickness contribute the most thermal efficiency gains (4.1 percentage points) and increased exhaust enthalpy (5.7%).