Abstract
Taking into account the oil resources depletion the requirements to fuel consumption of internal combustion engines are now increasing as well as to their reliability and durability. With the continual increase in the number of internal combustion engines in operation, along with the problem of parts of the cylinder piston group wearing out has caused exhaust from such engines to be one of the main source of harmful pollutant emissions in cities. Therefore, environmental requirements have in turn increased dramatically. The engine resource and its efficiency largely depend on the process of fuel combustion in the combustion chamber. Experimental studies aimed to improve the working process on diesel engines by piston insulation have shown an effective decrease in fuel consumption by reducing heat loss and more complete fuel combustion. When oxide ceramic coatings were used on the piston and cylinder head, the maximum power increased and the specific fuel consumption decreased. However ceramic coatings are not widely used due to their peeling. We have developed a technology for the galvanic plasma treatment of pistons, which made it possible to obtain on the pistons surface made of aluminum alloys a ceramic corundum layer with high adhesion to the base metal that does not peel and has electret properties. In 1993, pistons with a corundum surface layer were installed in a shunting diesel locomotive and life-time running tests were conducted. Such pistons increased wear resistance, reduced the wear of cylinder liners, increased the strength of the annular jumpers, and were not prone to burnouts and scuffing. They provided an increase in the resource of the cylinder-piston group of the diesel engine by more than 125 thousand engine hours. The paper provides an analysis of the effect of corundum pistons thermal insulation on significant increasing the, engine power and fuel consumption reduction. Basing on experimental bench studies of a gasoline engine, a tractor diesel engine and long-term operational life tests of diesel engines, an attempt had been made to explain the reasons for the improvement in the engines’ efficiency.
Highlights
There is a fleet of approximately 1000 diesel shunting ChME-3 currently in service in Ukraine
The resource of the new cylinder-piston group with standard pistons installed in the diesel engine of the ChME-3 diesel locomotive during routine maintenance is about 35-40 thousand hours
The modification of the working surfaces of pistons made of aluminum alloys was performed with the formation of a heat-insulating corundum layer on the firing surface of the piston, which made it possible to obtain fluctuations in the temperature of the piston surface following a change in gas temperature during the cycle
Summary
There is a fleet of approximately 1000 diesel shunting ChME-3 currently in service in Ukraine. They are trying to solve this problem by replacing the existing K6S310DR diesel engines with Caterpillar diesel engines, it is rather expensive. To limit the heat loss of the working fluid through the walls of the combustion chamber, heat insulating overlays, heat rings, screens are used as well as cermets or ceramic coatings which have high heat resistance, hardness and wear resistance and do not require changes in the design of parts. The repairs of on-line diesel engines K6S310DR in CHME-3 type locomotives with pistons that had undergone galvanoplasma surface treatment with the formation of a corundum layer is much cheaper It helps to solve the problem of diesel engines performance characteristics improvement in shunting locomotives of the CHME-3 type after repairs. The purpose of the publication is to inform about the benefits of the proposed piston corundum technology for internal combustion engines
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