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bond coat. Among the various causes of failure of
1. INTRODUCTION TBC, oxidation and thermal mismatch are identified
as two major factors affecting the life of the coating
The introduction of the paper should explain system. It is observed that the coating surface
the nature of the problem, previous work, purpose, temperature increase with increasing the thickness in
and the contribution of the paper. The contents of a decreasing rate. As for bond coat surface, increasing
each section may be provided to understand easily coating thickness, the normal stress decreases steadily
about the paper. and the maximum shear stress rises in a decreasing
rate. Although diesel TBCs operate at lower
Compressive loads and more frequent temperatures than aircraft engines, they are subjected
thermal shock than their aircraft counterparts. In to much greater compressive loads and more frequent
addition, many of these TBCs must cope with the thermal shock than their aircraft counterparts. In
contaminates found in lower-grade fuels. The addition, many of these TBCs must cope with the
difference between aircraft TBCs and diesel TBCs contaminates found in lower-grade fuels. The
are often ignored by coating applicators. Thermal difference between aircraft TBCs and diesel TBCs
barrier coatings can be applied on gas turbines, are often ignored by coating applicators. Thermal
automotive engines and diesel equipment. The use of barrier coatings can be applied on gas turbines,
TBC on diesel components such as valves, pistons automotive engines and diesel equipment. The use of
and fire decks insulates the metal substrates from TBC on diesel components such as valves, pistons
high-temperature oxidation and corrosive and fire decks insulates compressive loads and more
environments. As a thermal barrier, it reduces metal frequent thermal shock than their aircraft
temperatures surface are to reduce the heat flux into counterparts. In addition, many of these TBCs must
the piston, to protect the piston from thermal stresses, cope with the contaminates found in lower-grade
corrosive attacks due to fuel contaminants and fuels. The difference between aircraft TBCs and
reducing emissions. There are several applications of diesel TBCs are often ignored by coating applicators.
TBC in SI engines, showing improved performance Thermal barrier coatings can be applied on gas
and emissions. In SI engines, the top surface near the turbines, automotive engines and diesel equipment.
crevice is especially chosen as the place of TBC The use of TBC on diesel components such as valves,
deposition. Choosing this area also enables to pistons and fire decks insulates the metal substrates
decrease the risk of knocking. The coating thickness from high-temperature oxidation and corrosive
has an TBC on diesel components such as valves, environments. As a thermal barrier, it reduces metal
pistons and fire decks insulates the metal substrates temperatures ted in the oil- and water-cooling
from high-temperature oxidation and corrosive systems.
environments. As a thermal barrier, it reduces metal The performance of plasma sprayed based
temperatures (Scientist G), Head of Mechanical YSZ TBCs systems on aluminium alloys is a very
Behaviour Group Defence Metallurgical Research important in the automotive industry. In the keeping
Group Labin a direction parallel to the ceramic–bond view of application of aluminum alloys in the
coat interface (horizontal cracks), which leads to automotive industry, the durability of 2024 AA with
coating delamination. The other typical TBC failure TBCs systems was studied for high temperature
occurs by spalling of the ceramic top coat from the applications. This article investigate the thermal
1
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fatigue behaviour of plasma sprayed based YSZ were kept as 10 minutes. When the samples were
TBCs systems for 2024 aluminium alloy (AA). cooled to the ambient temperature, they were taken
out, dried and put into the high temperature furnace
2. DETAILS EXPERIMENTAL again, repeating the same process. More than 90% of
the cracked regions of the surface of TBC systems
2.1. Materials and Procedures were adapted as the criterion for the failure of the
Compressive loads and more frequent thermal coating. The weight changes of the samples were
shock than their aircraft counterparts. In addition, measured to a precision of 0.5 mg by an analytical
many of these TBCs must cope with the contaminates balance. Three number of specimens were tested and
found in lower-grade fuels. The difference between average was considered for analysis.
aircraft TBCs and diesel TBCs are often ignored by
coating applicators. Thermal barrier coatings can be 3. RESULTS AND DISCUSSION
applied on gas turbines, automotive engines and
diesel equipment. The use of TBC on diesel 3.1. TBC system Composition of
components such as valves, pistons and fire decks Microstructure of TBCoated alluminium
insulates the metal substrates from high-temperature alloys after thermal cycling till failure is shown in
oxidation and corrosive environments. As a thermal Fig. 1 (a and b). The failure of TBC coated surface on
barrier, it reduces metal temperatures After bond aluminium alloys under thermal fatigue conditions
coat, another coat was applied on the surface which is was found be in a cracking mode, which induces from
called top coat. Top coat was done of Yttria coated compressive loads and more frequent thermal
Stabilized Zirconia (YSZ) by APS. Parameters of top shock than their aircraft counterparts. In addition,
coat parameter are given in Table 3. many of these TBCs must cope with the contaminates
Table1: Chemical Composition of 2024 AA found in lower-grade fuels. The difference between
aircraft TBCs and diesel TBCs are often ignored by
coating applicators. Thermal barrier coatings can be
applied on gas turbines, automotive engines and
diesel equipment. The use of TBC on diesel
components such as valves, pistons and fire decks
Table 2: YSZ top coat Spraying for bond coat insulates the metal substrates from high-temperature
oxidation and corrosive environments. As a thermal
barrier, it reduces metal temperatures as well as bond
coat. The micro-columnar grains encircled in Fig.2.
was observed, which were solidified from the melted
fraction of YSZ top coat powder.
3.2. Thermal Fatigue behaviours of TBCs systems
Square specimen were selected to consider
the effect in practical application of thermal barrier
coating (TBC) system, such as edges and corners in
internal combustion (IC) engine piston. It can be seen
from Fig. 1 compressive loads and more frequent
thermal shock than their aircraft counterparts. In
Table 3: YSZ top coat Spraying Process addition, many of these TBCs must cope with the
Parameters for Process Parameters contaminates found in lower-grade fuels. The
difference between aircraft TBCs and diesel TBCs
are often ignored by coating applicators. Thermal
barrier coatings can be applied on gas turbines,
automotive engines and diesel equipment. The use of
TBC on diesel components such as valves, pistons
and fire decks insulates the metal substrates from
high-temperature oxidation and corrosive
environments. As a thermal barrier, it reduces metal
temperatures not occur. After 52 cycles, gradual
weight loss was observed indicating thermal
degradation of coated specimens. After 97 cycles, the
sudden weight loss of samples was observed, which
2.2. Thermal Fatigue Test implied the coating damage via the cracking mode.
The thermal fatigue test was done in a
thermal cyclic furnace. The specimens were tested at
6000C highest temperature. Heating and cooling time
2
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2. The failure of YSZ TBCs systems on
2024AA were observed due to the multiple
cracks mode only. The results show four types
of cracks formed in TBCs systems on 2024
AA, i.e., vertical cracks, horizontal crack,
propagating crack, and penetrating crack [16].
In this article, vertical cracks and propagating
cracks (or horizontal crack) emerged in YSZ
based TBCs systems for 2024AA. The
penetrating vertical cracks started penetrate
from top coat to the substrate surface at 6000C.
ACKNOWLEDGMENTS
TBC on diesel components such as valves,
Fig.1. (a & b) Optical Micrograph of Fractured plasma pistons and fire decks insulates the metal substrates
sprayed TBC specimens with thickness of 250µm after TF from high-temperature oxidation and corrosive
testing environments. As a thermal barrier, it reduces metal
temperatures (Scientist G), Head of Mechanical
Behaviour Group Defence Metallurgical Research
Group Lab, pistons and fire decks insulates the metal
substrates from high-temperature oxidation and
corrosive environments. As a thermal barrier, it
reduces metal temperatures (Scientist G), Head of
Mechanical Behaviour Group Defence Metallurgical
Research Group Lab (DMRL, Hyderabad) for their
cooperation.
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Fig.2. FESEM micrograph of the fractured surface of as-
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