The role of porous thermal barrier coatings on enhancing the internal combustion engine efficiency

Internal combustion engines have a key role in society and contribute to a significant part of the greenhouse gas emissions. In this way, higher efficiency is a continuing trend that does not show signs of declining. The thermal losses are identified as a potential factor to improve efficiency in engines. Therefore, the thermal losses are the preferential route due to its extensive impact on the overall losses. This paper investigates porous thermal barrier coatings applied to internal combustion engines in order to convert the thermal losses into indicated work.

The article explores two processes, Atmospheric Plasma Spray and Suspension Plasma Spray using different formulations of Yttria Stabilized Zirconia as feedstock. Laser Flash Analysis was used to determine the thermal properties of the coatings and Scanning Electron Microscopy (SEM) to analyze the microstructure. The behavior under thermal cyclic was assessed in coupons via flame rig test, and the thermal swing was evaluated in collaboration with Stony Brook University. The indicated work was determined based on a single-cylinder engine test. Microstructure analysis with SEM were performed before and after the tests to identify the failure mechanism. The results showed that porous TBCs have the potential to provide enhancements in engine efficiency.