Piston Ring Research Articles

Wear Characteristics Caused by Ti3AlC2 Particles under Impact-Sliding Conditions in Marine Engine

With the marine industry’s demands for carbon reduction and increased reliability, the friction and wear performance of marine engines is becoming increasingly important. MAX phase materials show great potential in marine engine tribopair materials due to their unique microstructure and performance. The typical MAX phase material Ti3AlC2 was combined with MoDTC and added to the lubricant containing ZDDP additive for the tribopair composed of chromium-based ceramic composite coated steel (CKS) piston rings and cast iron cylinder liners under impact-sliding conditions. Compared to Ti3AlC2 alone, the friction coefficient and wear depth of the designed composite additive MoDTC/Ti3AlC2 were reduced by 36.9% and 41.4%, respectively. The worn surface lubricated with the Ti3AlC2/MoDTC composite additive showed fewer scratches with significantly less plastic deformation and clearer honing grooves. The multi-component tribofilm containing FeS, MoS2, MoO3, ZnO, TiO2, Al2O3, unoxidised particles, short-chain phosphates, and some ZnS was present on the worn cylinder liner surface. The synergistic effect of Ti3AlC2, MoDTC and ZDDP additives in the lubricant can isolate the mutual contact, generate a solid tribofilm and reduce the scratching. This can provide some guidance for the development of high-performance lubricant additives under impact-sliding conditions.

Evaluation of Tribological Properties of Different Coatings on Automotive Piston Rings: A Review

Friction and wear play crucial roles in automotive engine performances and their efficiency. Overall, 40% of fuel power loss occurs in friction of various components of the engine. Frictional loss between piston rings and cylinder liner assembly contributes major loss of fuel power in the automotive engine and it is about 15% of total fuel power loss occurs due to friction. In the present scenario, thin film coating techniques are in trend to enhance the mechanical and tribological properties of machine components. In this paper, different types of wear-resistant, corrosion-resistant, and antifriction coating materials and their characteristics are discussed. Also, carbon-based coatings, nitride coating, carbide coating, oxide coating, and the intermixing of counterparts of coating material to form a composite coating, multilayer coating, and varying their percentage elemental composition composite are reviewed and compared. The synergistic effect of coating with texturing over the piston ring is discussed. Finally, recent developments and new possibilities of coatings that can be employed on piston rings are briefly discussed.

Tribofilm distribution and tribological analysis of piston ring-cylinder liner interfaces under realistic engine conditions

The study investigates tribofilm distribution and tribology performance on piston ring-cylinder liner surfaces under realistic internal combustion (IC) engine conditions. By examining the effects of load, temperature, and oil film thickness ratio, the research reveals that the tribofilm is significantly greater on the cylinder liner surface compared to the piston ring surface. The findings highlight that a specific excitation pressure is necessary for tribofilm formation. An oil film thickness ratio of 1.8041 is evaluated as an accurate boundary for tribofilm distribution on the cylinder liner surface. These insights provide valuable data for designing piston ring-cylinder liner interfaces and improving IC engine performance.

Tribological Comparison of Coatings Produced by PVD Sputtering for Application on Combustion Piston Rings

This article compares the tribological performance of coatings produced by PVD sputtering. Transition metal dichalcogenide (TMD) coatings doped with carbon (WSC and MoSeC) and nitrogen (WSN and MoSeN) and a conventional diamond-like carbon (DLC) coating are compared. The tribological evaluation was oriented towards the use of coatings on piston rings. Block-on-ring tests in a condition lubricated with an additive-free polyalphaolefin (PAO 8) and at temperatures of 30, 60, and 100 °C were carried out to evaluate the coatings in boundary lubrication conditions. A load scanner test was used to evaluate dry friction and scuffing propensity. In addition to WSN, all other TMD coatings (WSC, MoSeC, and MoSeN) exhibited lower friction than DLC in dry and lubricated conditions. The study reveals that WSC, among TMD coatings, offers promising results, with significantly lower friction levels than DLC, while demonstrating reduced wear and a lower risk of metal adhesion. These findings suggest that WSC may be a viable alternative to DLC in piston rings, with potential benefits for reducing fuel consumption and increasing engine durability.

REFINING THE EMPIRICAL MODEL OF THE HEAT TRANSFER BOUNDARY CONDITIONS OF THE PISTON OF A HIGH-SPEED DIESEL ENGINE

The level of temperature of ICE pistons is a factor that greatly affects their reliability. Therefore, the need to simulate the temperature state of pistons with sufficient accuracy and minimal allocation of resources and time exists in research and during design. Primary approaches for determining the boundary conditions of the problem of thermal conduction of the piston on the basis of criterion equations, high-level mathematical models, and empirical models are considered. The latter ones have become widespread by virtue of simplicity and ease of use in practice; their usability is limited to a certain set of operating modes of one engine or a few ones of a similar design. On the basis of data from four series of experimental tests for a well-studied diesel engine 4ChN12/14 the existing empirical models of boundary conditions, suitable for identifying the temperature state of the piston only within the respective separate series separately, are refined in the paper. Processing of the data set on the measured temperatures in the control zones of the piston was performed, and linear function approximations were found that satisfactorily describe the effect of diesel power on the specified temperatures. The model of boundary conditions for a set of eighteen separate regions on the surfaces of the piston was proposed, which takes into account the dependence of the piston temperature state on the brake power of the ICE, the crank angle of the start of fuel injection, and the conditions of cooling the piston with oil. The influence of the heat insulation layer on the piston crown surface on the heat transfer was accounted for by introducing an additional thermal resistance term into the boundary condition equations. The model made obtaining the temperature field of the piston possible in simulation that is consistent with the results of all series of experiments in the control zones of the piston periphery, the edge of the combustion chamber, the vicinity of the groove of the first piston ring, the cooled surface opposite to the combustion chamber, and the piston skirt. The importance of a gradual change in the temperature of the oil and coolant during the transition of the internal combustion engine from one mode of operation to another regarding the temperature state of the piston is demonstrated. Taking the temperatures of oil from previous modes of operation into account is recommended during the analysis of engine transient processes.

Simplified Wear Model for Power Cylinder under Engine Operating Conditions

A simple numerical approach is developed to predict the wear and friction of piston ring pack and cylinder liner during the break-in period and under transient speed conditions. In the model, a solution of mixed lubrications using the load-shearing concept is presented based on the selected elastic-plastic equations of asperity contacts in conjunction with well-established elastohydrodynamic equations. The model takes shear-thinning, thermal effects in elastohydrodynamic lubrication (EHL) and lubricant starvation effects into account. Modified Archard’s wear coefficient to describe the piston ring against cylinder liner wear is introduced. The approach is valid for the calculations of the asperity pressure at low values of the ratio of oil film thickness to combined roughness of the interacting surfaces, that is, less than 0.5. Applications are discussed, including association of piston side thrust force on wear and friction characteristics of piston ring/cylinder bore, gas blowby through the ring pack on the cylinder liner wear, a strong coating dependence for the piston ring wear, and wear distribution across the stroke under engine operating conditions. A good agreement between the experimental and analytical data indicates that the proposed model can be used to predict the wear and friction of the piston ring pack sliding against cylinder liner.

Detection of Piston Ring Deficiency in The Assembly of Automotive Ball Joint and Tie Rod End Parts

In today's intensely competitive environment, businesses strive to optimize production efficiency to reduce costs, increase profitability, and ensure customer satisfaction. This focus on efficiency and quality enables businesses to operate more effectively, gain a competitive advantage in the market, and move towards sustainable growth. This study uses image processing techniques to detect missing segments in the assembly of ball joints automatically. In the automotive industry, performing quality control of critical components before assembly and detecting and classifying the defective ones is essential. Many quality control methods can be applied with existing technologies. This paper proposes an automatic real-time control based on image processing techniques to detect ball joint missing segments, a common defect in the automotive industry. In the company, operators perform defect detection by visual inspection. In this system, production continues in cases where the operator cannot detect the defect. This system aims to detect the errors made by the operator during the assembly operations and provide instant feedback. The developed system uses OpenCV library algorithms that are highly accurate in detecting defects in manual assembly processes so that missing components are removed from the production chain, and production quality is significantly improved. Accuracy is over 94% when identifying missing segments, about 30% better than traditional methods. In tests, 1200 ball joints were run through the system, resulting in 1150 defects being correctly identified and removed from the production line. Accuracy is high thanks to the application of various image processing techniques such as grayscale conversion, edge detection, and shape recognition. This also provides real-time feedback to the operator so the system can reduce detection and response time from 15 seconds to 5 seconds. This increases production speed and reduces the error rate in manual assembly processes by 20%. This paper also highlights the potential of image processing technology in manufacturing. It will contribute to improved quality control mechanisms to increase the reliability and efficiency of production lines in the automotive industry.

Tribological properties under dry and lubricated sliding conditions of TiSiN and AlTiCrN coatings deposited on gray cast iron

In internal combustion engines, the majority of friction losses and wear occur between the cylinder liners and piston rings. Hard coatings applied to cylinder liners can increase the efficiency of internal combustion engines by improving tribological properties. The gray cast iron cylinder liner was coated with TiSiN and AlTiCrN employing the cathodic arc deposition process. The coatings were examined using nanoindentation tests, scratch tests, an optical profilometer, a scanning electron microscope, an X-ray diffractometer, and energy dispersive analysis to assess their hardness, adhesion, and structural characteristics. The reciprocating test was carried out to assess the coatings' wear and friction characteristics under lubricated and dry sliding with a ball at varying normal loads. The hardness of the TiSiN and AlTiCrN coatings was 45 GPa and 18 GPa, respectively. The cohesion strength, adhesion strength, and crack propagation resistance of AlTiCrN coating were approximately 2, 1.3 and 2.5 times higher than those of TiSiN coating, respectively. Both coatings exhibited remarkable wear performance at high normal loads. Under dry sliding conditions at 25 N normal load, the wear rate of AlTiCrN and TiSiN coatings were nearly 33 and 20 times, respectively, lower than the uncoated substrate. Under dry sliding conditions, the TiSiN coating exhibited the lowest wear rate at low normal loads (5 N and 15 N), while the AlTiCrN coating performed best at high normal loads (25 N). In lubricated sliding conditions, the AlTiCrN coating consistently showed the lowest wear rate across all normal loads.

A Comparative Analysis of Friction and Energy Losses in Hydrogen and CNG Fueled Engines: Implications on the Top Compression Ring Design Using Steel, Cast Iron, and Silicon Nitride Materials.

Optimizing the design of the top compression ring holds immense importance in reducing friction across both traditional Internal Combustion (IC) engines and hybrid power systems. This study investigates the impact of alternative fuels, specifically hydrogen and CNG, on the behavior of top piston rings within internal combustion (IC) engines. The goal of this approach is to understand the complex interplay between blow-by, fuel type, material behavior, and their effects on ring friction, energy losses, and resulting ring strength. Two types of IC engines were analyzed, taking into account flow conditions derived from in-cylinder pressures and piston geometry. Following ISO 6622-2:2013 guidelines, thick top compression rings made from varying materials (steel, cast iron, and silicon nitride) were investigated and compared. Through a quasi-static ring model within Computational Fluid Dynamics (CFD), critical tribological parameters such as the minimum film and ring friction were simulated, revealing that lighter hydrogen-powered engines with higher combustion pressures could potentially experience approximately 34.7% greater power losses compared to their heavier CNG counterparts. By delving into the interaction among the fuel delivery system, gas blow-by, and material properties, this study unveils valuable insights into the tribological and structural behavior of the top piston ring conjunction. Notably, the silicon nitride material demonstrates promising strength improvements, while the adoption of Direct Injection (DI) is associated with approximately 10.1% higher energy losses compared to PFI. Such findings carry significant implications for enhancing engine efficiency and promoting sustainable energy utilization.

The deposition properties of the tetrahedral amorphous carbon coating on the piston ring at different incident angles and substrate bias voltages: Molecular dynamics simulation

To reduce the friction and wear of the piston ring-cylinder liner system in the internal combustion engine, the tetrahedral amorphous carbon (ta-C) coating is deposited onto the piston ring. The deposition model is established and deposition process is simulated using molecular dynamics simulation. The visualization of simulation results is obtained using open visualization tool. The second nearest-neighbor modified embedded-atom method potential and Tersoff potential are employed to describe the interactions among the atoms and ions. The deposition properties of the ta-C coating at different incident angles and substrate bias voltages are studied. The layer coverage function, interface mixing, surface morphology, radial distribution function, layer density, layer sp3 fraction, and normal stress of the ta-C coating on the piston ring are analyzed. The simulation results show that a ta-C coating on the piston ring with a smooth surface, a dense amorphous structure, a high sp3 fraction, and a uniform mixing area can be obtained. The minimum RMS roughness is 0.539 Å at −150 V, maximum layer density is 3.560 g/cm3 at −1 V, and maximum layer sp3 fraction is 0.972 at 30°. This study provides theoretical support for the selection of experimental parameters.

Effects of double-sided textures matching on friction and wear performance in reciprocating contact interface

With increasing demands for friction reduction and wear resistance in heavy-duty diesel engines, the design of surface textures in reciprocating contact zone of the cylinder liner and piston ring (CLPR) has been a major concern. Through designed orthogonal tests for optimizing the double-sided textured CLPR, a maximum reduction in the friction coefficient of 12.63 % was achieved for the superior double-sided textured CLPR compared to the untextured surface, with corresponding reductions in the wear depth of the cylinder liner and piston ring of 16.73 % and 18.25 %, respectively. The relative position variation between the CLPR microtextures at the sliding contact area caused different stress values and stress distribution. Compared to the inferior double-sided textured CLPR, superior double-sided textured CLPR with lower stress concentration and symmetrical distribution within the contact area generated smoother and flatter worn platforms and non-spalling dimple edges with less abrasive wear. It can provide some insight into the matching design of double-sided CLPR surfaces under heavy load conditions.

Wear mechanisms and material deposition of high-performance polymer composites for hydrogen compression

The transistion to renewable energy production is a main component in achieving the climate targets defined in the 2015 Paris Agreement. Power-to-gas concepts, where electrical energy is stored as hydrogen gas, require the design and operation of state-of-the-art reciprocating compressor technology to realize high pressure ratios and high volumetric flow rates for gas supply demands. The main challenges in designing machines suited for these operating conditions are high thermo-mechanical stresses acting on the piston sealing rings. High shear loads and minimal ring gap sizes demand material pairings with excellent wear resistance and sliding properties. This work investigates the life cycle limiting wear mechanisms present in the piston compressor and develops advanced concepts for piston rings in cylinder tribo-contacts. PI and PPS polymers reinforced with carbon fiber were modified with dry lubricating PTFE to fulfil the requirements of this highly stressed tribo-system. Tribo-tests were performed against steel countersurfaces with a linear oscillating tribometer in pin-on-plate configuration. The failure mechanisms were analysed utilizing scanning electron microscopy on cross-sections cut into the depth of the countersurface material with focused ion beam milling. 2D scanning transmission electron microscopy mapping supported by energy dispersive X-ray spectroscopy were performed to analyze the depth profile of the deposited tribo-layer elements on the wear track.

Novel Approach to Analyzing Friction Losses by Modeling the Microflow of Lubricating Oil between the Piston Rings and Cylinder in Internal Combustion Engines

This work focuses on the evolution of lubrication wedge shaping in internal combustion piston engines, taking into account liquid microflows on curved surfaces and coating microgeometries. It introduces a new approach to the analysis of friction losses by simulating the microflow of lubricating oil between the surfaces of piston rings cooperating with the cylinder surface. The models used take into account three types of microgeometry and material expansion. Key results indicate that microirregularities with a stereometry of 0.1–0.2 µm significantly influence the distribution of oil film thickness in the phase of maximum working pressure, which is critical for the functioning of the seal ring. The innovation of the work consists of demonstrating that, despite small changes in the friction force and power in the piston rings, changes in the minimum values of the oil film thickness are significant. The work highlights the failure to take into account microgeometry parameters in friction models, which leads to significant errors in the simulation results, especially in terms of oil film continuity and the contribution of mixed friction. The simulations also indicate that advanced geometric models with high mesh resolution are necessary only for the assessment of changes in oil film thickness during the highest pressure increase in the combustion chamber and taking into account various mixed friction conditions. The results suggest significant progress in engine design and performance, confirming the importance of advanced fluid and mixed friction models in piston engine lubrication research.

EHD simulation study on the influence of measured ICE compression piston ring profiles on the lubrication film formation

In this simulation-based research, the authors investigate the influence of the contacting profile and its tilting orientation of original compression piston rings on their hydrodynamic properties in internal combustion engines (ICEs). They employ a systematic approach, detailing the computational framework and simulation parameters. Three different original piston rings belonged to the same engine are used for the simulation and corresponding experimental validation in this publication. Results and discussions highlight the directional dependence of hydrodynamic conditions, with distinct differences for individual rings. Original smoothed profiles are compared with substitute geometries like quadratic parabola and circular arc fits. The research contributes insights into the complex dynamics of compression rings in ICEs, providing a foundation for optimizing ring profiles for enhanced hydrodynamic properties.

Numerical Simulations and Experimental Validation of Squeeze Film Dampers for Aircraft Jet Engines

Squeeze film dampers are used to reduce vibration in aircraft jet engines supported by rolling element bearings. The underlying physics of the squeeze film dampers has been studied extensively over the past 50 years. However, the research on the SFDs is still ongoing due to the complexity of modeling of several effects such as fluid inertia and the modeling of the piston rings, which are often used to seal SFDs. In this work, a special experimental setup has been designed to validate the numerical models of SFDs. This experimental setup can be used with various SFD geometries (including piston ring seals) and simulate almost all conditions that may occur in an aircraft jet engine. This work also focuses on the inertia forces of the fluid. The hydrodynamic pressure distribution of a detailed 3D-CFD model is compared with the solution of the Reynolds equation including inertia effects. Finally, the simulation results are compared with experimental data and good agreement is observed.

A novel adaptive CUSUM system for efficient process mean monitoring: An application in piston ring manufacturing process

The adaptive versions of charting tools are well-established statistical monitoring techniques for detecting unknown changes in the process over a range of shifts. A re-weighted adaptive CUSUM mean (RACUSUM) charting scheme has been proposed in this study for monitoring the range of shifts. The proposed RACUSUM statistic estimates the unknown changes in the ongoing process using an EWMA statistic by plugging in an unbiased shift estimator and choosing a suitable smoothing constant according to the estimated shift to update the slack value of the CUSUM statistic. By employing Monte Carlo simulation using the zero- and steady-state processes, the proposal’s run-length (RL) profiles have been calculated. The proposed RACUSUM chart shows more sensitive behavior under the shift delay process than in the case of zero-state. A comparative analysis between the proposal and competitors has been presented using average RL, extra quadratic loss (EQL), and the relative mean index (RMI) as metrics for 1-sided and 2-sided charting schemes. The robustness of the proposed 2-sided RACUSUM chart against non-normality has also been reported. The proposal’s applicability has been demonstrated using two cases, one from the artificial and the other from a dataset of piston ring manufacturing industrial process.

Features of the operation of the lubrication system for lubricating ships' low-speed engines

The article examines the optimization of high-alkaline cylinder oil consumption in lubrication systems of marine low-speed engines (MODs), as well as the peculiarities of operation of the cylinder lubrication system in view of modern trends in the development of low-speed marine engines. An overview of the lubricator lubrication systems of the cylinders of marine main engines was carried out and possible prospects for improving the lubricator lubrication systems of the cylinders of marine diesel engines were considered. Attention is paid to the causes of occurrence and methods of combating a whole range of problems, which represent the possibility of increased wear of cylinder sleeves, pistons, piston rings, this is related to the type and grade of fuel and its sulfur content. Sulfur in the fuel is neutralized with the help of cylinder oils with high alkalinity, problems arise when changing the grade of fuel, this requires changing the brand of cylinder oil (CLO BN). The possibility of using a cylinder oil mixing system (ACOM) to neutralize sulfur in the fuel and improve protection against low-temperature corrosion of MOD cylinder liners is proposed and considered. This system mixes and doses cylinder oil depending on the load of the ship's engine and the type of fuel. ACOM allows the dosing of oil on marine engines operating in dual fuel consumption (SDF) modes, where the ratio between pilot (ignition) and gas fuel is defined, the system mixes two different types of cylinder oil into one with the required BN base number, it can be determined as the oil's ability to neutralize acids produced during use. The results of optimal consumption of cylinder oil, which ensures minimal wear of cylinder liners of a diesel engine, are given. Features of lubrication regimes and control of the technical condition of the cylinder group of marine low-speed diesel engines during their operation at reduced rotation frequency are described

Analisis Penyebab Kerusakan Mesin Diesel pada Generator Set untuk Tindakan Perawatan di Kapal Tanker MT. Sea Serenity

The generator set on the ship has the function of supplying electrical power needs. MT Tanker Ship. Sea Serenity is one of the ships that delivers goods between islands. In operation, the diesel generator engine on the MT. Sea Serenity sometimes experiences problems resulting in blackouts. This research aims to determine the factors that cause damage as well as appropriate maintenance actions and the method used is trouble shooting. Based on the research results, it is found that the causes of damage are: Engine knock, engine exhaust smoke, problems with the injection pump, worn plunger, damage to delivery valve seat, injection nozzle interference, valve opening pressure too low, engine output unstable, worn piston rings. Maintenance carried out: Injection timing must be adjusted according to ignition sequence, set injection timing, replace plunger and delivery valve seat, set valve opening pressure, replace spring, and clean injection orifice. On unstable engine output, the control rack stroke must be checked. Perform regular oil changes and regular tune ups

Investigation of lubrication and tribological behaviors in a diesel engine with the new designed flow-guided combustion chamber

Changes to the piston bowl geometry directly affect engine performance, exhaust emissions, combustion characteristics and air/fuel mixture formation. In this study, a new combustion chamber (NCC) geometry for a single cylinder direct injection diesel engine is presented, and experimentally compared with the standard combustion chamber (SCC) geometry. Each combustion chamber was fitted to the engine and performed long-term test for 100 h. The effect of combustion chamber bowl geometry on piston rings and lubricating oil was investigated. Firstly, soot was measured in the engine, and the NCC geometry reduced soot emission by approximately 12.32 % compared to the standard bowl geometry type at part load. With the NCC geometry, homogeneity fresh charge and flame propagation were achieved by providing wall-guided flow. The tribological effect of bowl geometry on the lubricating oil was investigated. In the oil analysis, Al,Ca,Co,Cr,Cu,Fe,Mg,Mn,Mo,Ni and Zn elements were higher in the SCC geometry than in the NCC geometry. Especially at the end of the 100th hour of operation, the presence of elements such as Fe and Al showed an increase in engine wears. The lubricating oil kinematic viscosity for SCC was 111.9 mm2/s at 40 °C and 127.9 mm2/s for NCC. In the new geometry, the flash point temperature of the lubricating oil was measured as 232 °C, while this value in the standard geometry was measured as 222 °C. This showed that the volatility and degree of contamination of the oil was lower with the new geometry. SEM/EDX analysis of the piston rings showed a significant difference between the first and second rings for the two geometries. The wear lines in the standard geometry were found to be deeper and more visible than in the new geometry.

Conjoint impact of modified HHO system, compression ratio variation, and tribological enhancement of steel piston ring substrates on performance and emission characteristics of a spark-ignition engine

In these times of efforts to develop high-efficiency hydrogen-adopted or hydrogen-fueled internal combustion engines (ICEs), and concerns related to electric vehicles such as battery cost, drawbacks in harsh winter climates, low range, etc., it is important to generate original ideas in line with the manufacturing of ICEs with improved efficacy. Accordingly, this study presents a comprehensive experimental investigation to observe the cooperated effects of pulse width modulation (PWM)-controlled hydroxy (HHO) gas introduction and improvement in tribological performance of piston ring-cylinder liner mechanism on performance and emission characteristics of a spark-ignition (SI) engine (co-system). The variation of compression ratio (CR), influence of two electrolyzer types of tube electrolyzer (TE) and plate electrolyzer (PE) for production of HHO gas, and zeta potential (ZP)-based dynamic light scattering (DLS) analysis to specify the optimal catalyst concentration in de-ionized water were also observed. Electron cyclotron resonance-chemical vapor deposition (ECR-CVD) method was utilized to bombard the piston ring substrates with diamond-like carbon (DLC) atoms under high energy plasma to improve the mechanical strength of the friction surface. Using linear tribometer, the uncoated (UPR) and coated piston rings (CPR) underwent friction tests to determine the wear rate (WR), and coefficient of friction (COF) which have substantial contribution to frictional losses. The surfaces of the samples were visualized via scanning electron microscopy (SEM) and atomic force microscopy (AFM) before and after abrasion tests to analyze carbon coating and its effects on tribological performance. The observations depicted that HHO flowrate needs to be varied as the engine load and CR change, and based on these observations, PWM control unit was designed, manufactured and reprogrammed so as to adjust electrical power consumption of HHO system when needed. The aforementioned analyses ensured optimization of the overall system so as to maximize the efficiency of the test engine. The co-system with optimized parameters (CPR + HHO + PWM) yielded an increase in average brake power (Pe) up to 31%, and average reductions in specific fuel consumption (β), carbon monoxide (CO), unburned hydrocarbon (UHC), and nitrogen oxide (NOx) emissions by 17%, 25%, 19%, and 14%, respectively at engine load range from 20% to 100%. It is expected that this study will be a good guide in terms of developing high-efficient ICEs due to promising results provided by the co-system.