An Analysis of Residual Stresses in Thermal Barrier Coatings: A FE Performance Assessment

Abstract

Internal combustion engines have been widely used for past 100 years. In the development of engine components a number of special techniques are used to compact the hostile operating environment, which usually includes high and cyclic forces, high and cyclic temperatures, sliding and often corrosion and/or erosion. In this study, 3-D finite element structural and thermal analyses were carried out on both uncoated (without coating) and ceramic-coated engine piston. A 150 mu m super alloy bond coating (NiCrAlY) was first applied to the piston. Then, piston was covered by 350 mu m thickness of MgZrO3 as top coating. The analysis can be utilized to detect possible thermal problem spots in an engine, and to provide input data for general engine modeling and engine lubrication and wear studies.