Piston Thermal Analysis of Heavy Commercial Vehicle Diesel Engine Using Lanthanum Zirconate Thermal-Barrier Coating

Abstract

When a commercial vehicle diesel engine works for an extended period of time at the torque spot, it can easily cause a mechanical failure due to the high temperature of the piston. In this paper, the temperature plug method was used to measure the temperature of the piston at the maximum torque spot. In order to reduce the failure caused by high temperature, the finite element analysis software Ansys was used in this paper to study the effects of different thicknesses of ceramic coatings on the piston surface of a diesel engine on the maximum temperature of the piston substrate. The bonding layer of the ceramic coating was NiCoCrAlY with a thickness of 0.1 mm, and the insulating layer was a La2Zr2O7 coating with respective thicknesses of 0.2 mm, 0.3 mm, 0.5 mm, 0.7 mm, and 0.9 mm. When the thickness of the ceramic coating was increased from 0.3 mm to 1.0 mm, the maximum temperature of the piston base decreased from 347.9 °C to 267.46 °C. This showed that the use of a thermal-barrier coating can effectively reduce the maximum temperature of the piston and greatly improve the safety of engine operation.