A numerical evaluation and guideline for thermal barrier coatings on gasoline compression ignition engines

Abstract

The application of thermal barrier coatings (TBCs) for internal combustion engines has drawn more research attention in recent years due to the improved coating technology and advanced material properties. This paper presents the combination of thermal barrier coatings with an advanced combustion concept: gasoline compression ignition (GCI). This study aims to evaluate the coating performance with GCI combustion on Aramco’s light-duty GCI engine. The thermodynamic engine model has been established and collaborated with CFD results to investigate thermal barrier coatings for GCI with a PPCI-diffusion combustion strategy primarily at a load of 23.5 bar IMEPg. Two real-world coating materials were pre-selected as Gen.1 and Gen.2 candidates. The investigation consists of three main topics: the effect of coating thickness on GCI, the effect of intake boost on the performance of traditional coatings and temperature swing coatings, and the effect of combustion chamber coverage on engine performance. The result shows that the TBC thickness became the key parameter to optimize for TBC with GCI combustion mode, and in the end, 250–500 microns is recommended based on the temperature limit of ceramic material. It was also found that the high level of intake boosting could significantly alleviate the charge heating penalty. The coverage of piston, engine head, and both intake and exhaust valves should be applied to achieve the highest efficiency gains. It was found that the gain ratio from each chamber component can be drastically different at different loads.