EXPERIMENTAL STUDIES ON CERMET COATING OF PISTON RING OF SINGLE CYLINDER DIESEL ENGINE

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IJEDR1702117 International Journal of Engineering Development and Research (www.ijedr.org) 689

EXPERIMENTAL STUDIES ON CERMET

COATING OF PISTON RING OF SINGLE

CYLINDER DIESEL ENGINE

1

Bhavesh Pindoriya ,

2

Deep Badheka

1

P.G. Student,2Asst. Professor 1

Mechanical Engineering, 1

Silver Oa k College of Eng ineering, Ah medabad,India.

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Abstract—ThePistonRing isVeryCriticalComponent and fortheImprovement, CermetCoatingisDonebyTheHigh Velocity

Oxygen Fl owMethods (HVOF). Among Ther mal Spr ayi ng Me thods, HVOF Spr ayings Most Easily Commonly Applicable Method in The Automoti ve Industries Because it has a High S pray Rate and De position, The Process Consumes Fuel Gases Which Are Ine xpe nsive and Easily Obtainable. The Technical ReliabilityofHVOFS ystemsisWellEstablished inIndustrial Applicati ons.InPartic ular, Mo+NiCrBSi Coatings by HVO Fhave Enhance d Resistance to Wear and Heat and Inconel625+ Cr3C2NiCr have high Strength Pr operties, High Te mper ature Resistance, Corr osion Resistance, Hi gh Har dness. In present study, various test like Radial Wall thickness, Ring end gap, Me tal de bris, Sulphate d ash par ticle, Viscosity of oil and Ring Weight and some perfor mance parame ter was exami ne d. Experimental has beenDone with Coated ring with (Mo+NiCrBSi and Inconel625+ Cr3C2NiCr)andWithout CoatedPistonRi ngs.

IndexTerms—Cermet, Mo+NiCrBSi, Inconel-625+Cr3C2NiCr, HVOF.

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I. IN TRO DUC TION

The powder used in this research (Mo-NiCrBSi) was a blend of powders composed of 25 % Mo and 75 % self-flu xing a lloy NiCrBSi. With the deposition of this powder a molybdenum base self-flu xing coating is obtained. This coating has high wear resistance, a low coeffic ient of frict ion and good scuffing resistance.

Second powder used in this research was a blend of powders composed of 80% Inconel625 and 20% self-flu xing Cr3C2NiCr alloy. Inconel 625-Cr3C2NiCr used for hard facings, hard bearing surfaces and abrasive wear resistant coatings. It is also compatible with the most of the materials, especially with iron -based alloys. These coatings have higher wear resistance (approximately 20%) and higher tensile bond strength comparing to the molybdenum coatings. Amongst the spraying materials, nickel-based alloys are being widely used because they display good resistance to wear, oxidation and high temperature, as well as being low cost. NiCrBSi alloy is one of the alloys with better performances and it is common ly used in mechanical co mponents such as rollers in cooling tables in hot strip mills, pump bushings and wearing plates sliding rings. The presence of boron and silicon in itscomposition lowers the melting point.silicon in itscomposition lowers the melting point of this type of alloys and gives them the “self-flu xing” character, which is especially suited HVOF coating process .

Coati ng Process

HVOF process is the most widely used coating method because it presents process fle xibility and coating quality in comb ination. Micro crac ks and porosity are undesired mic rostructural features because they increase permeability in the applicat ion requir ing resistance to corrosion. The quality of the coatings manufactured by thermal deposition techniques depends on several paramet ers such as the sprayed particle size, the deposition temperature, the co mbustion gases, the feed speed, the angle and rate of deposition, the spray distance, the temperature of the substrate, the pressure applied during the process and, of course, the deposition technique.HVOF uses a different torch design that enables the flame to e xpand when the spray nozzle is activated. This causes a surge in acceleration, which in turn accelerates the mixture partic les. When the mixture is released from the noz zle, the velocity of the mixture leads to a very thin and evenly applied coat. The final coating is we ll adhered, strong, and dense. I ts hardness, corrosion resistance, and overall wear resistance is superior to plasma spraying. In this study, mechanical p roperties of the Mo-NiCrBSi, Inconel625-Cr3C2NiCr coating deposited by High Ve locity Oxygen Fue l were ana lyzed. Cr3C2 NiCr HVOF therma lly sprayed coatings have been extensively applied on industrial co mponents working at high temperature to improve thei r erosion, corrosion and oxidation resistance.

HVOF Coating Benefits

 Reduced oxide content

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II.SPECIFICATIONANDPHYSIC AL VISUALIZATION

Table 1 Inconel625+Cr3C2NiCr Che mica l Co mposition

Ele ment C Mo W Ni Co Fe Mn Cr Si

Wt (%) 1.98 11.92 2.96 55.04 1.28 0.8 0.16 25.73 0.08

Table 2 Mo+NicrBsi Che mica l Co mposition

Ele ment Mo Ni Cr C Si Fe

Weightage (%) 25 53.25 12.75 0.6 3 3

Table 3 HVOF Para meter Table 4 Engine Specification

Para meter Specification

Engine type single cylinder 4-stroke d iesel engine AV1 KIRLOSKER

Bra ke powe r 5 HP o r 3.7kw

Speed 1500 rp m

Bore 80 mm

Stroke 110 mm

Types of Loading Rope Brake Dyna mo meter

Co mpression ratio 16.5:1

Injection pressure 185 bar

Swept Vo lu me 553 cc

Fuel type Diesel

Fig.1 Physical Visualization

III.RESULT OF EXP ERIMEN TS

Parame ter Value

L.P.G gas Flo w Rate [lph] 55 to 60 L.P.G gas pressure [kg/c m2] 5.5 to 6.0

O2 Gas Flow Rate [lph] 270 to 280 O2 Gas Pressure [kg/cm2] 10.5

Air Flo w Rate [lph] 450

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IJEDR1702117 International Journal of Engineering Development and Research (www.ijedr.org) 691 Observation of expe riment includes measure ment of Expe rimental pa ra meter. Continuous observation during the life cycle included Ring Weight, Radia l Wa ll Thic kness, Oil v iscosity, Ring end gap, Sulphated ash particle,Metal Debris , Brake Specific Fuel Consumption, Mechanical Effic iency, Exhaust Gas Te mperature, Indicative Mean Effective Pressure .

Followingistheresultandeffectofpistonringcoatingonthelifecycleof Sigle Cylinder Diesel Engine.

A. Ring weight

Fig 2 Ring Weight Vs Cycle Time

B. Radi al Wall Thickness

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C. Oil Viscosity

Fig 4 Oil Viscosity Vs Cyc le Time

D. Ring End Gap

Fig 5 Ring End Gap Vs Cycle Time

E Sul phate d Ash Particle

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F. Me tal De bris

Fig 7 Metal Debris Vs Cycle Time

G. Br ake Specific Fuel Consumption

Fig 8 BSFC Vs BP

F Mechanical Efficiency

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HExhaust Gas Te mper ature

Fig 10 Exhaust Gas Temperature Vs BP

G

Indic ati ve Mean Effecti ve Pressures

Fig 11 Indicative Mean Effective Pressure Vs BP

IV. CO NCLUSION

(1) Va rious test was pe rforme d on p iston ring that co mpa red with e ach oth er we show th at the resu lts sho w Mo+NiCrBSi is the best co mb inat ion of met a l and c e ra mic (c e rmet ) for s ing le cy lin de r d iese l e ng ine inst ead o f Inc one l625+Cr3C2NiCr.

(2) Du e to less wea r be t wee n the cy linde r wa ll and rin g F ace t he he at gen e rat ed is less and the gas p rodu ced fro m the bu rn ing o f th e o il film redu ces causes less po llut ion in at mosph e re .

V.REFER ENC ES

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[2] Lu iz G.D.B.S. Lima , Lu iz C.S. Nun es, Ro be rto M .Sou za , N.K. Fu ku masu a nd And re Fe rra rese : Nu me ric a l ana lys is o f th e in fluenc e o f film th ic kness and prope rt ies on th e st ress state o f th in fil m-coa ted p ist on rings un de r conta ct load , Su rfa ce & Coa t ings Te chno logy 215(2013) 327 -333.

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