Internal Combustion Engine Components Research Articles

Thermal cycle behaviour of plasma sprayed thermal barrier coatings on cast iron substrate for the application of liner of internal combustion engine

In the present scenario, research on Thermal Barrier Coatings (TBCs) is attracting significant attention in high-temperature applications due to the rising demand in industrial applications, such as gas turbine blades and internal combustion engine components. To meet these demands, it is essential to enhance the mechanical and oxidation properties of thermal barrier coatings. The atmospheric plasma spray methodology for producing these coatings has become a central focus in recent times. In this work, TBCs were prepared by blending pure alumina and Yttria-Stabilized Zirconia (YSZ) in equal proportions. Extensive study of TBCs carried out under high-temperature conditions through thermal cycle tests at elevated temperatures, around 850 °C. A total of 350 thermal cycles were conducted, and microstructures of the coating surface were examined at 150, 250, and 350 cycles. High-temperature stress, generated due to the sintering of the coating, also influences the life of the coatings. Specimen with a topcoat thickness of 300 μm, exhibited good thermal shock resistance compared to the specimens with topcoats of thickness of 100 μm and 200 μm. The effects of process parameters, porosity, and thermal shock resistance are presented in detail. The topcoat with a thickness of 300 μm demonstrated excellent thermal shock resistance and reduced formation of thermally grown oxide (TGO). The porosity of the coating, found to be between 2% and 3%, contributed to its dense nature, effectively reducing oxidation rates and enhancing the coating's lifespan under cyclic high-temperature conditions.

The effects of medium and friction pair on the tribological behavior of Mo-doped DLC films

Diamond-like carbon (DLC) films are widely used to improve the tribological properties of key components in internal combustion engines. However, their performance can be significantly affected by the service environment, which may impact engine reliability. This study investigates the impact of various media and friction pairs on the tribological behavior of molybdenum-doped DLC (Mo-DLC) films. The results demonstrate that Mo-DLC films exhibit excellent tribological properties across different media, showcasing their adaptability to various conditions. The lubrication mechanism varies with media viscosity: in methanol, Mo-DLC films operate under boundary lubrication conditions, leading to a relatively high wear rate of approximately 5.2 × 10−8 mm3/N·m. Conversely, in diesel and polyalphaolefin-based oil (PAO), where fluid dynamic lubrication occurs, wear rates are significantly lower, at 4.4 × 10−8 mm3/N·m and 3.1 × 10−8 mm3/N·m, respectively. In addition, the friction pair significantly influences the tribological performance of the Mo-DLC film. When paired with D-GCr15 in methanol, Mo-DLC films exhibit a low friction coefficient of 0.09 and a wear rate of 1.6 × 10−8 mm3/N·m, respectively. However, when coupled with N-GCr15, the increased surface roughness extends the running-in period and raises the friction coefficient in methanol. These findings offer valuable theoretical insights and practical guidance for optimizing DLC films in internal combustion engines.

Theoretical and numerical investigation of introduced errors in surface temperature measurements of pistons applied in internal combustion engine

DMP (Differences in Material Properties) often exists between temperature sensors and combustion chamber components of ICE (Internal Combustion Engine), resulting in IEs (Introduced Errors) in the temperature measuring process. In this paper, we present a comprehensive theoretical analysis of the correlation between introduced errors on chamber components and the DMP. The analysis process considers the characteristics of the chamber's heat transfer BC (Boundary Condition). Then, simulations are used to investigate the introduced error of hardness plug and thermocouple sensors on the top surface of an ICE aluminum alloy piston. The theoretical analysis results indicate that heat transfer BC can be segmented into the time-averaged and fluctuation parts, and IEs are linearly superimposed under these two parts of BCs. The heat conductivity impacts the time-averaged error and the product of heat conductivity, density, and heat capacity impacts the fluctuation error. The experimental and simulation results indicate that the max time-average error of the hardness plug on piston is 2.4 °C, with a fluctuation introduced error of 3.6 °C and a total introduced error of 6 °C; and the time-average introduced error of thermocouple sensor is 9.4 °C, with a fluctuation error of 5.8 °C and a total introduced error of 15.2 °C. Finally, a fluctuation error correction method is proposed to reduce error. After correction, the error is reduced by 71 % and 66 % for hardness plug and thermocouple, respectively.

Study of Corrosion, Wear, and Thermal Analysis of Materials for Internal Combustion Engines and their Compatibility: A Review

Several types of research have been carried out on using alternative biofuel in internal combustion engines to salvage the depletion of fossil fuels. While most of these studies focused on the emission characteristics and control of global warming, little attention has been given to the corrosion, wear, thermal behaviour, and compatibility of the internal combustion engine materials to biodiesel. Thus, this study focused on the various corrosion and wear mechanisms associated with the internal combustion engine components like piston and cylinder heads, as well as the thermal behaviour efficiencies of the engine after interaction with the biodiesel fuels. The review cut across the wear study of internal combustion engine materials in varying fuel environments. Thermal analysis of different materials applied for internal combustion engines for sustainable fuel media. Corrosion study of various materials employed in the application of ICE engines. Also, the study discusses some significant challenges related to the compatibility of ICE with biodiesel and gaseous fuels. The study’s outcome indicates that an adequate fuel blend with nano additives can help improve the combustion process, emission reduction, and thermal efficiency of the internal combustion engine components. Furthermore, practical design in the internal combustion engine components like pistons will help compatibility with the material in the biodiesel blends, thus reducing wear, corrosion, and other failures associated with the internal combustion engine.

Production of Raphanus Sativus Biodiesel and Its Performance Assessment in a Thermal Barrier‐Coated Agriculture Sector Diesel Engine

Herein, in order to estimate the optimized process specifications, an empirical study is done for biodiesel production, performance of standard and coated engine, combustion, and discharge aspects of Raphanus sativus (radish) biodiesel. Optimization process parameters of biodiesel production are done using the response surface method. The importance of this study is that optimized biodiesel production is used to improve the biodiesel properties and fatty acid content to find suitable vegetable oil as well as a new coating material for sustainable development of the country in the field of agriculture and ecological conditions. The mechanism used in this research work is a coating for internal combustion engine components done with partially stabilized zirconia, aluminum–20% silicon carbide (Al–20%SiC), and titanium dioxide that acts as a ceramic composite settled above the coating that has a thickness of 450 μm by the technique called air plasma spray for test purpose. To increase the performance of an engine and reduce the emission particles like smoke density, carbon monoxide, and hydrocarbon except NO x , the partially stabilized zirconia, aluminum–20% silicon carbide (Al–20%SiC) coated engine is used under various compositions of radish biodiesel and clean diesel. To reduce NO x , the engine operation is carried out along with the TiO2 coated combustion chamber steam, and water injection technique is added to overcome the NO x formation. From this study, the resulting factor shows that adding 25% radish biodiesel (B25) and 75% clean diesel shows a reasonable reduction in emissions with comparatively better performance and combustion in the engine under consideration.

Diagnosing Cracks in the Injector Nozzles of Marine Internal Combustion Engines during Operation Using Vibration Symptoms

In the operation of internal combustion engines, despite technical state monitoring, some cracks that develop in metal components go undetected, leading to secondary, critical, or degradation damage. The diagnostic systems used in floating objects mainly use quasi-static thermodynamic signals, which alert operators too late about emerging damage. Although various methods have been developed to detect cracks in internal combustion engine components, the effectiveness and implementation of the proposed methods are not satisfactory. Therefore, this article presents the use of selected vibration and in-cylinder pressure signals to diagnose the development of damage in some components of marine diesel engines. The investigations were conducted under the natural conditions of the operation of sea-going vessels during port-handling operations. During these investigations, it was possible to observe clear changes in the values of diagnostic symptoms, which corresponded to the development of damage. The developing damage detected in the study involved cracks in injector nozzles manufactured from alloy steel. Despite advances in design, materials, and manufacturing technology, injector nozzle cracks still occur. The diagnostic symptoms used to detect damage development were the amplitude and spectral and wavelet measurements of vibration acceleration signals. This work aimed to search for crack-oriented methods of signal analysis, for example, computer visualization and the recording of diagnostic parameters in various domains. Decimation, windowed, time, amplitude, and time-frequency domain analyses; wavelet statistics; color analysis; and machine learning were used for classification using artificial neural networks. Experimental investigations showed the possibility of diagnosing the development processes of damage to marine diesel engines. The advanced signal processing methods used made it possible to obtain many signal measurements, from which the most useful diagnostic symptoms were selected. The new symptoms found with decimation, time-domain windowed analysis, and Haar wavelet statistics were more useful than the existing ones.

DIAGNOSTICS OF INTERNAL COMBUSTION ENGINES, STATE AND PROSPECTS IN THE ENGINEERING SERVICE
 OF THE AGRO-INDUSTRIAL COMPLEX

The paper presents the trends in the development of technical diagnostics in the engineering service of the agro-industrial complex, the most promising areas of its development. (Research purpose) The research purpose is analyzing the state of modern technical diagnostics in the engineering service of the agro-industrial complex, considering the development of new methods and technical diagnostic tools based on computer and information technologies. (Materials and methods) Modern information technologies, automated control and management systems were used during the research. The expansion of the range of devices and equipment to collect and proceed the information about the operational reliability of internal combustion engines of high-energy agricultural machinery allows for comprehensive research in the technical diagnostic. (Results and discussion) Authors used the integrated approach when conducting research in terms of developing methods of contactless diagnostics, assessing the level of maintenance using this diagnostic method, analyzing methods of contactless diagnostics that allow us to respond to the output signals of malfunctions of internal combustion engine components. Contactless diagnostics of internal combustion engines can reduce the number of failures by 1.5 or more times, increase the repair service life by 1.2-1.5 times, reduce maintenance costs by 15-20 percent, reduce fuel consumption by 12-15 percent and increase the durability of parts by 10-12 percent. (Conclusions) The research forms the scientific basis for the effective use of contactless diagnostics. The introduction of this method of technical diagnostics of internal combustion engines makes it possible to reduce the operating costs of agricultural producers by 12-15 percent due to the economical using of resources, to ensure a reduction in the number of repairs and a reduction in the number of spare parts purchased.

Design and Analysis of EN19 Centre Crankshaft

Crankshaft is the one of the most important components in internal combustion engines, it converts the translation motion of piston generated due to gas force into rotational moment of engine shaft though oscillatory motion of connecting rod. It mostly experiences the bending and torsional moment. The present research is focused on investigation of alternative material for crankshafts. Material EN19 is considered in this study and strength performance is verified under different operating conditions. Analytical design calculations, 3D modelling and analysis of EN19 crankshaft is carried out under maximum bending moment and maximum torque. 3D modeling and analysis was done in Creo parametric software and Ansys respectively. The compressive stresses, Von-Mises stresses, shear stresses and deformation in crankshaft are found to be within the permissible limits. Result shows cost effective material EN19 can be used as one of the alternative materials for crankshaft as it satisfies the all-strength requirements.

Analysis of the Degradation Trend in AISI 4140 Steels Used in Internal Combustion Engine Components.

Analysis of the Degradation Trend in AISI 4140 Steels Used in Internal Combustion Engine Components.

Production of the cylinder head and crankcase of a small internal combustion engine using metal laser powder bed fusion

This effort investigates the use of metal additive manufacturing, specifically laser powder bed fusion (LPBF) for the automotive and defense industries by demonstrating its feasibility to produce working internal combustion (IC) engine components. Through reverse engineering, model modifications, parameter selection, build layout optimization, and support structure design, the production of a titanium crankcase and aluminum cylinder head for a small IC engine was made possible. Computed tomography (CT) scans were subsequently used to quantify whether defects such as cracks, geometric deviations, and porosity were present or critical. Once viability of the parts was established, machining and other post-possessing were completed to create functional parts. Final X-ray CT and micro-CT results showed all critical features fell within ±0.127 mm of the original equipment manufacturer (OEM) parts. This allowed reassembly of the engine without any issues hindering later successful operation. Furthermore, the LPBF parts had significantly reduced porosity percentages, potentially making them more robust than their cast counterparts.

Experimental Investigation of Engine Valve Train Friction Considering Effects of Operating Conditions and WPC Surface Treatment.

Reduction in friction ensures fuel economy, control on emissions and durability of components in internal combustion engines. A modern gasoline internal combustion engine was instrumented to determine the friction values at the cam-roller interface considering the effects of surface treatment and engine operating state. A series of tests under different operating speeds and lubricant inlet temperatures were undertaken using both an original surface roller and a Wonder Process Craft (WPC) surface-treated engine roller. The results clearly revealed a substantial reduction in friction magnitude for the WPC surface-treated engine roller in comparison to the original roller while operating under similar conditions, indicating their strong potential for employment in engines. An increase in friction with the rise in temperature was also observed for both types of rollers, whereas increased lubricant entraining velocity due to higher operating speed had the opposite impact. A considerable reduction in frictional drive torque ranging from 8% to 28% was observed by employing the WPC-treated roller in comparison to original/untreated roller at various operating conditions, which signifies the strong potential for employment of WPC surface treatment in the roller/follower valve train engines.

FORCED ANALYSIS POCESS OF REED ROLL THREAD FOR SPARK PLUG

Spark plug is component or device of internal combustion engine (ICE) for make a compression and transfer energy to vehicle. Component of spark plug is center electrode, gasket, hexagon, insulator, corrugation, and terminal nut, the all component will assembly for internal combustion engine component. Thread is a critical component for connection spark plug and engine. the key of perfect thread is reed roll process when the motor makes a shell of part, the forced and rpm should be stable and do not over force for eliminate failure part. This study will discuss of forced analysis on thread and structure analyze from material spark plug after process. The result show in this case useing 2000 rpm and force 197,8N. Based on spot test material after threading, no any crack finding, only black dot due processing. Tortion test after assemblu 5 Kgf, for the lowest sample 1 is 8 Kgf, middle is sample 2 is 12 Kgf, and the bigger is 13 Kgf for sampling test. Igintion on sprak plug are normaly for ignition voltage lower is 13,3 kV, middle 15,3 kV, high 17,5 kV, and average is 15,3kV.

Data-Driven Sliding Bearing Temperature Model for Condition Monitoring in Internal Combustion Engines

Condition monitoring of components in internal combustion engines is an essential tool for increasing engine durability and avoiding critical engine operation. If lubrication at the crankshaft main bearings is insufficient, metal-to-metal contacts become likely and thus wear can occur. Bearing temperature measurements with thermocouples serve as a reliable, fast responding, individual bearing-oriented method that is comparatively simple to apply. In combination with a corresponding reference model, such measurements could serve to monitor the bearing condition. Based on experimental data from an MAN D2676 LF51 heavy-duty diesel engine, the derivation of a data-driven model for the crankshaft main bearing temperatures under steady-state engine operation is discussed. A total of 313 temperature measurements per bearing are available for this task. Readily accessible engine operating data that represent the corresponding engine operating points serve as model inputs. Different machine learning methods are thoroughly tested in terms of their prediction error with the help of a repeated nested cross-validation. The methods include different linear regression approaches (i.e., with and without lasso regularization), gradient boosting regression and support vector regression. As the results show, support vector regression is best suited for the problem. In the final evaluation on unseen test data, this method yields a prediction error of less than 0.4 °C (root mean squared error). Considering the temperature range from approximately 76 °C to 112 °C, the results demonstrate that it is possible to reliably predict the bearing temperatures with the chosen approach. Therefore, the combination of a data-driven bearing temperature model and thermocouple-based temperature measurements forms a powerful tool for monitoring the condition of sliding bearings in internal combustion engines.

Engine-in-the-Loop in practical application: A sensitivity study toward the influence of test bench parameters

The complexity of automobile powertrains continues to increase, leading to increased development time and effort. One method to address this challenge is to shift vehicle calibration and testing tasks to simulations with Engine-in-the-Loop (EiL) test setups. This increases the efficiency of the development process through high flexibility, low prototype costs, an early starting point, and a high degree of automation. EiL emulates the dynamic interactions between the internal combustion engine and other powertrain components by closed-loop coupling to real-time simulation models. The coupling quality strongly depends on the interface properties, the hardware layout, and the control functionality of the dynamometer test bench. This paper analyzes an existing test bench and presents the impact of altered test bench parameters on different EiL quality aspects. Thereto, the setup is analyzed and a Simulink based grey box test bench model is derived. The latter is parametrized with a full factorial approach in comparison to real test bench measurements. The test bench model is then used for simulative investigations considering different test bench parameters: Two different use cases of Model-in-the-Loop (MiL) supported EiL are investigated. First, a simulative improvement of the test bench control quality by altering the PI based dyno speed controller parameters is investigated. The virtually calibrated controller parameters are applied to the real EiL system and compared to vehicle measurements. Second, sensitivity studies are shown with respect to dynamometer inertia and system dead time in terms of control quality and energy. As a major outcome, a compromise of control accuracy and stability for different speed controller parameters, dyno inertia, and system dead time is shown. Furthermore, it is demonstrated that EiL has only a small deviation in terms of energy compared to a full vehicle, making it a valid approach when considering CO2 emissions.

Classification of contaminants in diesel engine oils

Introduction. The deterioration of engine oil in an internal combustion engine (ICE) is directly related to the ingress of various pollutants into the crankcase. Depending on the type of contamination, the type of sediment on engine part surfaces varies. It should be noted that the functioning of the motor oil is extremely affected by the oxidation process, and organic acids produced during the process contribute to corrosion of ICE parts. Water, diesel, cooling fluid, soot particles, asphaltenes, etc. also cause irreparable damage.Materials and methods. This paper presents the results of an extensive literature review aimed at studying the main types of motor oil pollutants. Classifications are given for the aggregate state of pollutants, as well as for possible ways of their penetration into the lubricant. Liquid pollutants are the most narrowly considered in this article. To demonstrate the negative effect of contaminants entering the engine oil, photographs of internal combustion engine parts with sediments on the surfaces of the internal combustion engine components are presented.Results. The classification of the main pollutants of motor oils is given; the consequences arising from the ingress of foreign compounds into the lubricant in question are indicated.Conclusion. The effect of contaminants on the parts of the internal combustion engine and the lubricant has been established. On the basis of the classification, it is possible to judge the causes of entry and the possible consequences of the impact of contamination on the operation of the engine.

Heat transfer and pressure loss performances for additively manufactured pin fin arrays in annular channels

Additive manufacturing technology with metal powder has facilitated the production of innovative and even more complex heat sinks. The layer-additive process offers a wide range of geometries that may be exploited for advanced cooling purposes and the final identification of the best heat sink configuration has to deal with other constraints imposed by the specific application. This contribution focuses on the thermal and fluid dynamic characterization of water cooling annular channels for applications in internal combustion engine components, where also the load-bearing capacity is requested together with the cooling performances. The heat transfer inside the annular channel was enhanced by pin fins arrays that were manufactured by selective laser melting technology in AISI 316L stainless steel. Four pin fins arrays that differ in dimensions and geometries were experimentally tested over a range of mass flow rates to compare their pressure losses and heat transfer performances against those of the smooth annular channel. Furthermore, the test coupons were analysed through optical non-destructive techniques to characterize their geometrical morphology in terms of conformity with the designed model, surface roughness and waviness. In the investigated channel Reynolds number range (from 2000 to 12,000), the pin fins arrays with the largest height-to-pin diameter ratio show better thermal performances (Nu/Nu0 always greater than 2), however their heat sink efficiencies are above unity only for Re < 3000. In addition, the 45° oriented pin arrangement seems the most promising geometry due to high thermal efficiency, lighter weight and slightly lower manufacturing cost.

Microstructural evolution and mechanical properties of thixoformed Al-Si-Cu alloy connecting rods

Connecting rod is considered one of the most crucial mechanical components of internal combustion engines. The materials and processing methods of such components are the matter of research that mainly focuses on the enhancement of its performance while contributing to the overall weight reduction of the vehicles. They should have very high strength to ensure long service life because of the high levels of cyclical loading they are subjected to. A lot of effort has been put to manufacture such components via the use of thixoforming as this method could enhance the mechanical properties by minimizing the defects existed in as-received alloys. In this study, the thixoforming process of Al-Si-Cu aluminium alloy was carried out. The cooling slope method was used to prepare the feedstock for thixoforming. The results revealed the superior integrity and quality concerning the performance of alloys produced by the thixoforming processing. Microstructure studies show the enhancement and the reduction in casting porosity with the transformation of dendritic arms to mostly globular of α-Al. Subsequently, mechanical properties of the thixoformed parts were remarkability improved and reached the values of 107 HV, 197 MPa and 250 MPa for hardness, yield stress, and ultimate tensile strength, respectively.

Time resolved growth of (N)-polycyclic aromatic hydrocarbons in engine deposits uncovered with OrbiSIMS depth profiling.

Carbonaceous deposits are ubiquitous, being formed on surfaces in engines, fuel systems and on catalysts operating at high temperatures for hydrocarbon transformations. In internal combustion engines, their formation negatively affects worldwide vehicle emissions and fuel economy, leading to premature deaths and environmental damage. Deposit composition and formation pathways are poorly understood due to their insolubility and the intrinsic complexity of their layered carbonaceous matrix. Here, we apply the in situ high mass resolving power capabilities of 3D Orbitrap secondary ion mass spectrometry (3D OrbiSIMS) argon cluster depth profiling on 16 lab grown deposits and evidence common molecular distributions in deposit depth and in positions relative to the combustion chamber. We observe the products of the growth of both planar and curved polycyclic aromatic hydrocarbons to form small fullerenes over time in the engine and propose possible formation pathways which explain the molecular distributions observed. These include alkyl scission, cyclisation of aliphatic side chains and hydrogen abstraction C2H2 addition to form larger aromatic structures. We apply this pathway to previously unidentified nitrogen containing structures in deposits including quinolines and carbazoles. For the first time, 3D OrbiSIMS results were compared and validated with data from atmospheric pressure matrix assisted laser desorption ionization MS. The comprehensive characterization provided will help the development of a new generation of chemical additives to reduce deposits, and thus improve vehicle emissions and global air quality.

Design and Fabrication of Electric Motorcycle

The vehicles on road are increasing with rapid rate which is good by transportation perspective and hence the growing need of oil-based fuel making transportation costly as the price of oil based fuel rising too. The quantity of oil-based fuel remains unchecked and the exhaust from oil-based fuel brings environmental problems like ‘‘green house effect’’, health issues for the operating environment. The electric vehicles is a good option for moving away with problems related to the oil-based fuel lot of researches is going on in world and money is being spent on the development of the electric vehicles. The problem related with electric vehicles are electric vehicles have low speed, having low load carrying capacity, and batteries having short life. The main aim of this research paper is to give an idea about fabrication of simple, cost effective electric motorcycle which can be done by replacing internal combustion engine and other components with brush less direct current gear motor, controller and lithium-ion battery. This electric motorcycle uses 48V 750w brushless direct current gear motor to propel the vehicle, lithium-ion battery as power source the brushless direct current motor. The 48v 750w brushless direct current gear motor have high load carrying capacity with acceptable speed and lithium-ion battery have more life than other batteries available in market such as lead acid battery. The lithium-ion battery has less weight, quick charge property, required less storage space compare to other batteries available in market.

Development and characterization of multiwalled carbon nanotube-reinforced microwave sintered hybrid aluminum metal matrix composites: An experimental investigation on mechanical and tribological performances

Nowadays, scientists and engineers are coming together enthusiastically to develop superior lightweight materials for tribological applications, such as hybrid aluminum metal matrix composites for the internal combustion engine components. In the present study, hybrid aluminum metal matrix composite has been fabricated with A390 (Al–Si) as the matrix material and SiC (15 wt%) and multiwalled carbon nanotube (0.5 wt%, 1.5 wt%, and 2.5 wt%) as hybrid reinforcements, by following the microwave sintering route (2.45 GHz, 900 W). Microstructure and porosity of fabricated hybrid aluminum metal matrix composite has been characterized using micrographs of the scanning electron microscope and optical microscope. This is followed by the Vickers hardness characterization and composition analysis by X-ray diffraction and Raman spectroscopy. Thereafter, a comprehensive tribological investigation is carried out for A390, Al + 15% SiC, Al + 15% SiC + 0.5% MWCNT, Al + 15% SiC + 1.5% MWCNT, and Al + 15% SiC + 2.5% MWCNT. The present study reveals that the addition of multiwalled carbon nanotube (MWCNT) in microwave sintered aluminum metal matrix composite has a significant effect on wear resistance and frictional response.