Piston Material Research Articles

Study on wear behaviour of aluminium-based piston alloy using different coatings

The wear rate of a piston in an engine determines how long it can run and how much power it can produce. The wear rate of lightweight piston materials used in medium cars was examined. The piston itself was used to cut the plates after it had been formed in an aluminium alloy. It was then successfully prepared for coating with hard anodizing and tin coating after being trimmed to a diameter of 90 mm. There are a number of wear tests, including the pin on the disc test, slurry abrasion test, scratch test, and erosion test to analyse the wear rate. The coating's substance and intended applications determine which wear test is used. Slurry erosion and corrosion tests for the coating are favoured for usage on automobiles. But the pin on disc and scratch tests are frequently carried out in cases where the coating is applied dry. In the current investigation, only one variable load (30 N, 40 N, and 50 N) and sliding speed (500 rpm) was chosen for the wear test. Sliding distance (1200 m) was treated as a constant. Under dry conditions, a pin-on-disc machine was used to test the wear of the coatings and soft materials. SEM analysis was used to examine the surface morphology of the coating's worn surfaces. It was discovered that as the load grew, the coating's wear rate also did. It was discovered that as the load was raised, the coating's co-efficient of friction decreased. With the aid of an optical telescope, the microstructure of the coating's worn surfaces was also inspected, although no evidence of a change in the microstructure owing to frictional heat was discovered. It was discovered that the coating's micro hardness decreased away from the wear track at the coating's cross section. Using a SEM, adhesion, deformation, and microcutting were the main wear mechanisms seen.

Algorithmic linearization improves Syringe-based extrusion in elastic systems using Hydrogel-based materials

Accuracy and precision are essential in extrusion-based material handling such as three-dimensional (3D) bioprinting. However, the elasticity of components, backlash, variability of nozzle and cartridge shapes, etc. can lead to unpredictable printing results, which is further complicated by the wide range of rheologically diverse materials and complex sample designs.To address this issue, we present an algorithmic approach to compensate for the discrepancies between piston motion and material extrusion in syringe-based extrusion systems. This approach relies on cyclical, iterative optimization through rapid piston movements, which are adjusted based on extrusion analysis.In this work we establish a general theoretical framework for extrusion and link the rheological properties of prepared hydrogels with shear rates in a typical bioprinting process. The determined properties are compared with the success of the developed algorithm to modify machine instructions for precise material deposition of short, interrupted lines, as well as multi-layered scaffold structures.Overall, our approach provides a means of improving the accuracy and precision of complex extrusion-based bioprinting systems, without prior knowledge of set-up or material properties, making it highly versatile and suitable for a wide range of applications, particularly when the combined set-up and material properties are too complex for solely predictive approaches.

Study on electrodeposition of CoNiW coating on 1045 steel as piston ring materials and its wear resistance performance

The CoNiW alloy coating is electrodeposited on the 1045 steel as piston ring materials by electrodeposition method to greatly improve the wear resistance performance. The electrodeposition of CoNiW belongs to a kind of induced co-deposition. The tungstate ions in the plating solution are beneficial to increase the deposition mass. Moreover, tungsten atoms could occupy the lattice junction of nickel and cobalt atoms to generate lattice distortion, which will reduce the grain size, decrease the surface roughness and improve the wear resistance performance. Compared with Co coating and CoNi coating, the CoNiW electrodeposited coating has the best wear resistance performance with the smallest surface roughness (0.179 µm) and the thinnest wear scar (7.4 µm average depth).

A Multi-Criteria Decision-Making Approach for Piston Material Selection under Single-Valued Trapezoidal Neutrosophic Sets

It is one of the most difficult and time-consuming processes to develop and pick an acceptable material for the piston material that has a variety of attributes. Component failure is often caused by inappropriate material at some stage throughout the functioning process. In light of this, the piston material selection is performed in this article. The goal of this work is to found a technique for selecting the material of the piston for a new design engine by using the multi-criteria decision-making (MCDM) approach to find a solution to the issue of choosing the material for the piston. The purpose of the TOPSIS method is to pick the appropriate material for a piston based on the application it will be used in. The TOPSIS technique is stretched under neutrosophic sets to solve the vague and uncertain information in this process. The single-valued trapezoidal neutrosophic sets (SVTNSs) are used in this paper. The SVTNSs is a mixed with the trapezoidal neutrosophic sets (TNSs) and the single-valued neutrosophic sets (SVNSs). There are nine criteria and three alternatives used in this paper. The illustrative example is carried out The sensitivity analysis and comparative study are carried out to display the robustness and efficiency of the suggested model.

Analysis of Some Tribological Properties of Hazelnut Oil in Gasoline Engines

In this article, oil obtained from vegetable was used to lubricate a single-cylinder 2-stroke gasoline engine as lubricating oil, and tribological function of the obtained oil was investigated. To investigate the tribological functions of the lubricating oils, a 2-stroke single-cylinder gasoline engine was used. For mineral oil and hazelnut oil, the test engine was run for 100 hours for each one and were used to lubricate in the test engine as lubricating oils. Samples were prepared for the aim of the determining the wear on the cylinder surface, and also EDS (Energy Dispersive Spectrograph) analysis were obtained. The results of the analyses showed that, the wear on the cylinder surface were increased in the studies using hazelnut oil and the C content of the cylinder sample increased compared to the study with mineral oil. Al element was detected in the cylinder sample in the hazelnut study, that the reason for this, is the transport of the Al element during the friction event in the piston material to the cylinder surface.

The introduced error associated with the contact-type detection for piston surface temperature in combustion engines using coaxial thermocouples and its eliminating algorithm

Piston surface temperature is critical original data in combustion engines for evaluating its heat load and studying the in-cylinder combustion and heat transfer, where a contact-type measurement method employing coaxial thermocouples is frequently used. But packaging coaxial thermocouples into a piston is bound to change the original temperature field of the piston to be tested, bringing about the introduced error, which is a key problem for the piston surface temperature detection. In this paper, a two-dimensional model of a coaxial thermocouple is established, based on which the introduced error is quantitatively evaluated firstly, followed by a discussion on the mechanisms of the introduced error next. Then three temperature correction methods are proposed aiming to reduce such serious introduced errors, and the correction effects are demonstrated for E, J, and K-type coaxial thermocouples with different film thicknesses. It is found that the introduced errors are remarkable for all the tested thermocouple types and hot junction depths, which are closely related to the corresponding impulse response deviations, more essentially, to the deviations between thermal product values (ρck) of the thermocouple material system and that of the prototype piston material. The introduced errors are effectively reduced by the three correction methods for most cases, among which Method-II behaves best, followed by Method-III, Method-I. Method-II can steadily reduce average relative error, an indicator of the introduced error, by more than two orders of magnitude to 0.09‰ around.

SIMULATION AND ANALYSIS OF ALSI10MG ALLOY FOR PISTON MATERIAL IN ADDITIVE MANUFACTURING

- This report presents a detailed study on the design and analysis of the Piston Head of the Internal Combustion Engine with the Additive manufacturing technique of Laser Powder Bed fusions. The variety of materials for additive manufacturing is discussed and the compatible material AlSi10Mg Alloy was selected for Piston. It also focuses on the various simulations of manufacturing the Piston part by utilizing “Autodesk Netfabb Simulation 2020.1”. The residual stresses, hotspots, and, lack of fusion spots from simulation results are discussed and the suitable heat treatment analysis and temperature are studied for relieving the stresses. The microstructure, and strength evolution of the as-built AlSi10Mg part by LPBF, with the “Ansys Software”, Piston Materials are compared with AlSi10 Mg.

Effects of material and piston diameter on the fatigue behavior, failure mode, and stress distribution of feldspathic ceramic simplified restorations

This study evaluated the influence of the piston material (glass fiber-reinforced epoxy resin or stainless steel) and the piston tip diameter (6 or 40 mm) on the fatigue mechanical behavior, failure mode, and stress distribution of feldspathic ceramic simplified restorations. Pistons were machined in glass fiber-reinforced epoxy resin (ER) and in stainless steel (SS), with active tips simulating the curvature radius of 6- or 40-mm diameter spheres. A total of sixty (N= 60) feldspathic ceramic discs (Ø= 10 mm; thickness= 1.0 mm) were adhesively luted onto supporting substrate discs (Ø= 10 mm; thickness= 2.5 mm) and allocated into 4 groups (n= 15) according to the piston used for fatigue testing: ER_6, ER_40, SS_6, SS_40. Afterwards, the specimens were submitted to the cyclic fatigue test (20 Hz frequency; initial load= 100 N; step= 50 N; 10,000 cycles/step, upon specimen failure detection). The collected data were analyzed by two-way ANOVA (α= 0.05) to verify differences by considering ‘piston material’ and ‘piston diameter’ as factors, and their association. In addition, a survival analysis (Kaplan Meier with Mantel-Cox log-rank post-hoc tests) was conducted (α= 0.05). Fractographic and finite element (FEA) analyzes were also performed. ‘Piston material’ (p= 0.040, F= 4.43) and ‘piston diameter’ (p < 0.000, F= 563.21) had a significant influence on the fatigue failure load (FFL) and the number of cycles for failure (CFF) values. Feldspathic restorations showed higher FFL and CFF (p < 0.05) when tested with a 40 mm diameter piston compared to a 6 mm diameter piston (ER_40 and SS_40 > ER_6 > SS_6). In relation to the piston material, ER and SS pistons with 40 mm diameter promoted similar fatigue performance (ER_40: 946.67 N/179,333 cycles = SS_40: 936.67 N/177,333 cycles), while 6 mm diameter groups presented different fatigue performance (ER_6: 440 N; 78,000 cycles > SS_6: 353.3 N; 60,667 cycles). Hertzian cone crack failures were only observed in the groups tested with 6 mm pistons, regardless of piston material. Higher stress concentration on the ceramic surface was observed when using 6 mm diameter pistons, whereas the SS_6 group showed a slight increase in stress concentration in comparison to the ER_6 group. The piston diameter showed an influence on the fatigue behavior, failure mode, and stress distribution of feldspathic ceramic simplified restorations. However, the influence of piston material is only observed when 6 mm diameter pistons are used. The 40 mm diameter pistons led to radial crack, being more appropriate for fatigue test of simplified feldspathic ceramic restorations with a thickness ≤ 1 mm. Whilst the 6 mm diameter pistons should be avoided, once tend to induce Hertzian cone crack failures and to underestimate fatigue performance.

KARAKTERISASI PENGECORAN POROS BERULIR (SCREW) DENGAN VARIABEL PADUAN UNSUR TITANIUM BORON DAN MAGNESIUM

Aluminum is a non-ferrous metal that is widely used in everyday life, both on a large and small industrial scale as well as a household scale. In this research, used diesel motor piston material for casting screw. The addition of 0.1%, 0.3% Titanium Boron (Ti-B) and 0.1%, 0.3% Magnesium (Mg) for screw making by casting is expected to improve the physical and mechanical properties of the material. Tests carried out in this research are to wear testing and microstructure. The analysis of the results of this wear test shows that the aluminum alloy for making screws with the addition of 0.1% Titanium-Boron (TiB) and 0.1% Magnesium (Mg) has a better wear resistance, which is 1.154 mm² / kg compared to the addition of the element 0.3% Titanium-Boron (TiB) and 0.3% Magnesium (Mg) and without the addition of any elements which have wear resistance values of 1.252 mm² / kg and 1.596 mm² / kg, respectively. Microstructure testing shows the grain structure in aluminum alloy from casting results with the addition of Ti-B and Mg elements getting smaller and denser. This proves that the more elements of Ti-B and Mg added to the casting of aluminum alloys, the smaller the structure of the grain will be and will affect the mechanical properties of the screw.

Benchmark using multi criteria decision making (MCDM) technique to optimally select piston material

Piston is one of the critical components of an engine as combustion flame directly hits the piston surface. The aim of this research is to develop a methodology to select the material of piston for a new design of engine by using multi-criteria decision making (MCDM) method to solve the piston material selection problem. The Analytical Hierarchy Process (AHP) is designed to select material of the piston for a particular application. Open source data related to critical parameters of Caterpillar engine (viz. temperature and peak cylinder pressure) are considered, which directly affect the strength of piston material. To accurately predict the values of these parameters Ansys forte FEA simulation tool is used for combustion analysis. Simulation results are used as input to design material selection benchmark using AHP methodology. From the results obtained from Ansys forte simulation used as input to AHP based MCDM design methodology turned out to be fruitful for selecting Piston material for rapid decision making at the designer level.

FEA Analysis and Experimental Investigation of the Ceramic Coating on Aluminum Piston Material By Plasma Spray Coating Technique

Abstract: Functionally graded materials are of widespread interest because of their superior properties such as corrosion, erosion and oxidation resistance, high hardness, chemical and thermal stability at cryogenic and high temperatures. These properties make them useful for many applications, including Thermal Barrier Coating (TBC) on metallic substrates used at high temperatures in the fields of aircraft and aerospace, especially for thermal protection of components in gas turbines and diesel engines. The application of TBC reduces the heat loss to the engine cooling-jacket through the surface exposed to the heat transfer such as the cylinder head, liner, piston crown and piston rings. The insulation of the combustion chamber with ceramic coating affects the combustion process and, hence, the performance and exhaust emissions characteristics of the engines improve. In this project, the main emphasis is placed on the study of thermal behavior of functionally graded coatings obtained by means of using a commercial code, ANSYS on aluminum and steel piston surfaces and the results are verified with numerical and experimental works. Keywords: Thermal Barrier Coating, Piston, Insulation, Corrosion, ANSYS, engine cooling-jacket.

Evaluation of High-Temperature Martensitic Steels for Heavy-Duty Diesel Piston Applications

&lt;div class="section abstract"&gt;&lt;div class="htmlview paragraph"&gt;Five different commercially available high-temperature martensitic steels were evaluated for use in a heavy-duty diesel engine piston application and compared to existing piston alloys 4140 and microalloyed steel 38MnSiVS5 (MAS). Finite element analyses (FEA) were performed to predict the temperature and stress distributions for severe engine operating conditions of interest, and thus aid in the selection of the candidate steels. Complementary material testing was conducted to evaluate the properties relevant to the material performance in a piston. The elevated temperature strength, strength evolution during thermal aging, and thermal property data were used as inputs into the FEA piston models. Additionally, the long-term oxidation performance was assessed relative to the predicted maximum operating temperature for each material using coupon samples in a controlled-atmosphere cyclic-oxidation test rig. A current commercial steel piston alloy, quenched and tempered martensitic steel 4140, was tested in a single-cylinder research engine for a baseline oxidation and mechanical performance assessment using an abbreviated (50h) durability test plan. The predicted suitability of a candidate piston material in an engine is primarily based on its elevated temperature strength, oxidation resistance, and the complex influence of thermal conductivity, the latter of which is substantially lower for the candidate materials considered in this research relative to the traditional alloys. Although the lower thermal conductivity causes the candidate alloys to operate in higher temperature ranges under identical engine operating conditions and piston geometries, increasing the likelihood of partially or completely negating their strength and oxidation resistance advantages relative to 4140 and MAS steels, this evaluation indicates that several of the candidate piston alloys are predicted to enable improved oxidation resistance under more severe engine operating conditions relative to the current piston materials. However, further evaluation is required to determine if the elevated temperature fatigue strength and durability of these alloys are suitable for more severe engine conditions.&lt;/div&gt;&lt;/div&gt;

Effect of alloying elements on surface temperature field of aluminum piston in diesel engine

For three kinds of Aluminum-Silicon (Al-Si) alloy piston materials with different alloying element contents, the parameters such as thermal diffusion coefficient, specific heat capacity and thermal conductivity were measured, and the effects of Cu and Ni on the thermal properties of the materials were studied. Under the same processing conditions, three kinds of engine aluminum alloy pistons of different materials were manufactured. The piston surface temperature under the rated working condition of the diesel engine was measured by the hardness plug temperature calibration method. The distribution of piston surface temperature field was simulated by ANSYS finite element analysis, and the surface temperature analysis results of key parts of the piston were obtained. The results show that the finite element simulation results of piston surface temperature field are consistent with the temperature measurement results of hardness plug test, and the temperature change of key specific locations of piston possesses the similar trend. The thermal conductivity of aluminum alloy piston material increases with the increase of temperature. There is an obvious temperature gradient from the piston head to the piston skirt. High thermal conductivity can reduce the surface temperature of the piston head. The addition of alloying elements such as Cu and Ni will reduce the thermal conductivity of aluminum alloy materials and increase the surface temperature of piston. Therefore, proper controlling of the content of alloying elements can control the heat resistance and high temperature performance of piston materials.

A study on design and analysis by varying piston material in SI engine

The piston in an internal combustion engine is exposed to high temperature and pressure for a long time. Generally, when designing a piston, the material used must have a high melting point and tensile strength. In this paper, the design research and structural analysis of the piston of a four-stroke spark ignition (SI) engine was carried out by changing the composition of the piston material with various materials such as titanium alloy, magnesium alloy, gray cast iron, aluminum alloy and structural steel. The study investigated mechanical strain and the mechanical stress, deformation, heat dissipation, and heat-flux. This study concluded that under assumed conditions, depending on other piston parameters, titanium alloy creates optimal conditions for the piston.

Study on the tribological characteristics of plant oil-based bio-lubricant with automotive liner-piston ring materials

The development of bio-lubricant is an immerging area of research considering the rapid depletion of petroleum reserve and environmental concern. This study aims to develop non-edible jatropha oil-based bio-lubricant and investigate the tribological properties considering commonly used piston ring-cylinder liner materials of stainless steel and cast iron due to their interaction under lubricated conditions in an internal combustion engine. The bio-lubricant was prepared by blending different percentages of vegetable oil with commercial lubricants. The tribological test was carried out using a Reo-Bicerihigh-frequency reciprocating rig (HFRR) for the duration of 6 ​h under standard operating conditions. Different properties of bio-lubricants were measured before and after the HFRR test using various analytical instruments. The morphology of the worn material surfaces was examined via Hitachi S-4700 FE-SEM cold field emission high resolution scanning electron microscopy (SEM). The result showed that addition of vegetable oil lubricant up to 7.5% concentration can be compared with commercial lubricant in case of wear rate and coefficient of wear as weight loss reduced significantly. Minimum change in viscosity was observed at the addition of 7.5% bio-lubricant. Surface morphology analysis confirmed less damage of metal surface when tribological analysis were performed at mixed lubricated condition.

Evaluation of thermal processing and properties of 422 martensitic stainless steel for replacement of 4140 steel in diesel engine pistons

The thermal and mechanical properties of martensitic stainless steel 422 were evaluated for suitability as a drop-in replacement for 4140 steel in next generation heavy-duty diesel engine (HDDE) pistons. The time and temperature of the austenitization and tempering steps were studied to achieve optimum materials performance in piston applications, including the balance of thermal and mechanical properties and resistance to long-term thermal aging. Reducing the tempering temperature from 700 to 600 °C caused a substantial increase in elevated temperature strength from 25 to 600 °C, but had no significant influence on thermal conductivity, suggesting that thermal conductivity in 422 is dominated largely by composition and distribution of alloying elements and mostly independent of the sub-grain structure size and precipitate size. Compared to the current HDDE piston alloy 4140, 422 exhibits substantially higher elevated temperature strength and lower thermal conductivity, the latter which will cause 422 to operate at higher temperatures in pistons, possibly requiring a piston redesign to take advantage of the improved high temperature strength of 422. Piston material selection and alloy design strategies with potential to mitigate some of the shortcomings of martensitic stainless steels, such as 422, as drop-in replacements are discussed.

Influence of excess silicon phase on the thermal expansion behaviours of Al-Si binary casting alloys

Al-Si casting alloys are the most commonly used materials for piston alloys. The coefficient of thermal expansion is the key property of a piston material for improving the overall performance and service life of an engine. In the present study, the relationship between the morphology of the excess silicon phase and the coefficient of thermal expansion of Al-Si binary casting alloys was discussed. Optical and scanning electron microscopy were utilized to observe the morphology of the excess silicon phase in the Al-Si binary casting alloys before and after solution aging treatment. The results showed that the morphology of the excess silicon phase significantly influenced the coefficient of thermal expansion of the Al-Si binary casting alloys. After solution aging treatment, the coefficient of thermal expansion of the Al-Si binary casting alloys increased due to the rounding and granulating of the excess silicon phase precipitated during the casting process and decreased due to the precipitation of the finely dispersed Si phase in the α-Al matrix. The change in the coefficient of thermal expansion depended on which of the two kinds of morphological transformation of the excess silicon phase is dominant.

Influence of piston material on the fatigue behavior of a glass-ceramic

Statement of problemThe lack of standardization regarding the loading piston material used in fatigue tests could limit the interpretation of study findings. PurposeThe purpose of this in vitro study was to evaluate the effect of the piston material on the fatigue behavior of a lithium disilicate glass-ceramic. Material and methodsPlate-shaped, 1.2-mm-thick, lithium disilicate glass-ceramic specimens were cemented onto a dentin analog substrate with resin cement. The specimens were divided into 4 groups according to the piston material used in the fatigue test (n=30): metal, glass fiber-reinforced epoxy resin, ceramic, and human tooth. The fatigue test was performed in a mechanical cycling machine by using the boundary technique at 2 Hz in distilled water at 37 °C. The fatigue data were analyzed by using the Weibull distribution and a lifetime-inverse power law relationship. Failures were evaluated with fractography and transillumination. ResultsThe Weibull modulus (β) was similar among groups. The exponent of crack growth (n) was significantly greater for glass fiber-reinforced epoxy resin and tooth groups than for metal and ceramic; therefore, the probability of failure (Pf) of glass-ceramic specimens loaded by resin and tooth pistons depended more on load amplitude. Specimens tested with tooth showed the highest value of K (characteristic lifetime), which is an indication of greater survival. Radial crack was the only failure mode observed for all experimental groups. ConclusionsThe piston material influenced the fatigue survival of the lithium disilicate glass-ceramic. The glass fiber-reinforced epoxy resin piston closely simulated the fatigue behavior induced by the human tooth on the evaluated glass-ceramic.

Numerical Thermo-Mechanical Strength Analysis of an IC Engine Component

This research investigates a thermo-mechanical strength of three geometrical shape designs of an internal combustion (IC) engine piston by a finite element analysis (FEA). FEA was performed using Solidworks software for modelling geometrical piston designs, and the models were imported into ANSYS software for thermo-mechanical fatigue simulation. The work focused on predicting high stress intensity and indicated the fatigue critical regions and life of the piston shape design. AL7075-T6 aluminium alloy was used as a piston material and thermo-mechanical fatigue simulation was conducted based on the experimental stress-number of cycles recorded data from literature. Analytical results showed the similarity of the critical failure positions to some real failures in the IC engine piston, and the shape design modification of the piston. Hence, this concept can be used to satisfy the IC engine design needs at low cost.

COMPARATIVE EVALUATION OF THE CREEP OF PISTON ALUMINUM ALLOYS

The paper deals with the issues of reliability of piston materials in the process of increasing engine power. It is precisely the increase in the liter power of engines while ensuring environmental and economic requirements that is today one of the main areas of work in engine manufacturing. Studies have shown that material creep has significantly affects on the reliability of internal combustion engine parts. The most thermally loaded engine element is a piston. The main critical areas for it can be identified: the edge of the combustion chamber, the area of the piston rings and the piston skirt. The appearance of seizures on the piston skirt is sometimes observed even during the engine initial tests at the engine power increasing. Thus, we can speak about the relevance of the problem of identifying the reasons for reaching the critical state of the piston material. Based on these data, it becomes possible to develop measures to ensure the reliable operation of the piston. Among the most common materials for the manufacture of pistons are aluminum alloys AL25 and AK4. The chemical composition of these alloys varies considerably. The study obtained coefficients for calculating the creep rate for these materials. The identification of the calculation of the creep deformation of aluminum alloys at different stress levels, for different temperatures is carried out. The upper boundary of the region of model adequacy in terms of temperatures and stresses is determined. The creep rate of aluminum alloys is analyzed at different temperatures. In the conclusions, a comparison of the piston materials is made and the advantages of the AK4 alloy in comparison with the AL25 alloy, which are coming out when the engine power is increased, are indicated. The direction of further research is also indicated, which is associated with the analysis of the deformation of the considered materials at the first stage of creep.