Evaluation of Thermal Barrier Coating in Low Cycle Fatigue Life for Exhaust Manifold

Subject Areas : Journal of Simulation and Analysis of Novel Technologies in Mechanical Engineering

Hojjat Ashouri ¹

1 - Assistant Professor, Sama Unit, Varamin Unit

Received: 2019-09-01 Accepted : 2020-01-06 Published : 2019-11-01

Keywords: low cycle fatigue, thermal barrier coating, Morrow and SWT approaches, exhaust manifolds, confluence cracks,

Abstract :

This paper presents low cycle fatigue (LCF) life prediction of a coated and uncoated exhaust manifolds. First Solidworks software was used to model the exhaust manifolds. A thermal barrier coating system was applied on the tubes c of the exhaust manifolds, consists of two-layer systems: a ceramic top coat (TC), made of yttria stabilized zirconia (YSZ), ZrO2-8%Y2O3 and also a metallic bond coat (BC), made of NiCrAlY. The temperature-dependent of material parameters was considered in order to increase the accuracy of LCF life results. Then Ansys Workbench software was used to determine stress and fatigue life based on Morrow and Smith-Watson-Topper (SWT) approaches. Thermal fatigue failure of the engine components easily happens due to excessive temperature gradient and thermal stress. Modern exhaust systems must withstand severe cyclic mechanical and thermal loads throughout the whole life cycle. The results of finite element analysis (FEA) showed that the thermal barrier coating system reduces the temperature about 29°C because of its lower thermal conductivity. As a result, the exhaust manifolds tolerates lower temperature and fatigue life will increase. The results of thermo-mechanical analysis indicated that the stress in the coated exhaust manifolds decreased approximately 25 MPa for the sake of depletion of temperature gradient which can lead to higher fatigue lifetime. The results of LCF proved that the number of cycles of failure for coated exhaust manifold is approximately in the order 2-fold longer, than the results obtained from the uncoated exhaust manifolds.

References:

[1]     L. Meda, Y. Shu, and M. Romzek,“Exhaust System Manifold Development,” SAE Technical Paper No.2012-01-0643, 2012.

[2]     P-O. Santacreu, L. Faivre, and A. Acher, “Life Prediction Approach for Stainless Steel Exhaust Manifold,” SAE Technical Paper No.2012-01-0732, 2012.

[3]     Z. Yan, L. Zhien,  W. Xiaomin, H. Zheng, and Y. Xu, “Cracking failure analysis and optimization on exhaust manifold of engine with CFD-FEA coupling, ” SAE Technical Paper No. 2014-01-1710, 2014.

[4]     S. Sissaa, M. Giacopinia, and R. Rosia,  “Low-Cycle Thermal Fatigue and High-Cycle Vibration Fatigue Life Estimation of a Diesel Engine Exhaust Manifold, ” Journal of Procedia Engineering, vol. 74 , 2014, pp. 105-112.

[5]     M. Chen, Y. Wang, W. Wu, and J. Xin, “Design of the Exhaust Manifold of a Turbo Charged Gasoline Engine Based on a Transient Thermal Mechanical Analysis Approach,” SAE Technical Paper No.2014-01-2882, 2014.

[6]     L. Zhien, X. Wang Z. Yan, X. Li, and Y. Xu,  “Study on the Unsteady Heat Transfer of Engine Exhaust Manifold Based on the Analysis Method of Serial, ” SAE Technical Paper No.2014-01-1711, 2014.

[7]     X. Li,  W. Wang, X. Zou, Z. Zhang,  W. Zhang, S. Zhang, T. Chen, Y. Cao, and Y. Chen, “Simulation and Test Research for Integrated Exhaust Manifold and Hot End Durability,” SAE Technical Paper No .2017-01-2432, 2017.

[8]     M. Ekström,  A. Thibblin, A. Tjernberg,  C. Blomqvist, and  S. Jonsson, “Evaluation of internal thermal barrier coatings for exhaust manifolds, ”Journal of surface & coating technology, vol. 272, 2015, pp. 198-212

[9]     H. Ashouri, “Thermo-mechanical analysis of a coated cylinder head, ” Journal of Simulation & Analysis of Novel Technologies in Mechanical Engineering, Vol  10, 2017, No. 2, 35-48.

[10]  M. Rezvani rad,  G.H. Farrahi, M. Azadi, and M. Ghodrati, “ Stress analysis of thermal barrier coating system subjected to out-of-phase thermo-mechanical loadings considering roughness and porosity effect,” Journal of surface & coating technology, vol. 262, 2015, pp. 77-86.

[11]  G. Sivakumar, and S. Kumar, “Investigation on effect of yttria stabilized zirconia coated piston crown on performance and emission characteristic of diesel engine,” Alexandria engineering journal, doi.org/10.1016/j.aej.2014.08.003, 2014.

[12]  F. Szmytka, P. Michaud, L. Rémy, and A. Köster, “Thermo-mechanical fatigue resistance characterization and materials ranking from heat-flux-controlled tests. Application to cast-irons for automotive exhaust part,” Journal of Fatigue, vol. 55, 2013, pp. 136–146

[13]  A. Benoit, M.H. Maitournam, L. Rémy, and Y. Oger,  “Cyclic behaviour of structures under thermomechanical loadings: Application to exhaust manifolds,” Journal of Fatigue, vol. 38, 2012, pp. 65–74

[14]  H. Ashouri, “Thermo-mechanical fatigue simulation of exhaust manifolds, ” Journal of Simulation & Analysis of Novel Technologies in Mechanical Engineering, Vol  11, 2018, No. 2, 59-66.

[15]  M.A.Salehnejad, A. Mohammadi, M. Rezaei, and H. Ahangari,  “Cracking failure analysis of an engine exhaust manifold at high temperatures based on critical fracture toughness and FE simulation approach,” Journal of Engineering Fracture Mechanics, DOI.org/10.1016/j.engfracmech.2019.02.005, 2019, pp. 1-54

[16]  A-D. Azevedo Cardoso, and D. Claudio Andreatta, “Thermomechanical Analysis of Diesel Engine Exhaust Manifold,” SAE Technical Paper No.2016-36-0258, 2016.

[17]  G.M. Castro Güiza,  W. Hormaza,  R. Andres, E. Galvis, and L.M. Méndez Moreno, “Bending overload and thermal fatigue fractures in a cast exhaust Manifold, ” Journal of Engineering Failure Analysis, doi: 10.1016/j.engfailanal.2017.08.016, 2017.

[18]  M. Durat, M. Kapsiz, E. Nart, F. Ficici, and  A. Parlak, “The effects of coating materials in spark ignition engine design, Journal of material and design,” vol.  36, 2012, pp. 540-545.

[19]  M. Rezvani rad, M., Azadi, G.H. Farrahi, “Thermal barrier coating effect on stress distribution of a diesel engine cylinder head,” 7th Iranian Student Conference on Mechanical Engineering, School of Mechanical Engineering, University of Tehran, Tehran, iran, 2013.

[20]  M. Quazi, and S. Parashar, “Effect of Thermal Bearing Coating on Performance and Emission of Off Road Vehicle,” SAE International, Paper No. 2015-26-0065, 2015.

[21]  J. Lemaitre, and J. Chaboche, Mechanics of Solid Materials, Cambridge University Press, Cambridge, 1990.

[22]  J. L. Chaboche, “Time-independent constitutive theories for cyclic plasticity, ” International Journal of Plasticity, vol. 2,  No. 2, 1986, pp. 149–188

[23]  J. L. Chaboche, “A review of some plasticity and viscoplasticity constitutive theories,” International Journal of Plasticity, vol. 24, 2008, pp. 1642–1693

[24]  J.B. Heywood, Internal combustion engine fundamentals, McGraw-Hill press, 1998.

[25]  Y. He, P. Battiston, and A. Alkidas,  “Thermal Studies in the Exhaust Manifold of a Turbocharged V6 Diesel Engine Operating Under Steady-State Conditions,” SAE Technical Paper No.2006-01-0688, 2006.

[26]  R. Stephens,  A. Fatemi, and H. Fuchs. Metal fatigue in engineering, 2nd edition, John Wiley, 2001.

[27]  Y. L. Lee, J. Pan, R. B. Hathaway, and M. E. Barkey, Fatigue Testing and Analysis:Theory and Practice, Elsevier Butterworth-Heinemann, 2005.

[28]  L. Wang, Y. Wang, W.Q. Zhang, X.G. Sun, J.Q. He, Z.Y. Pan and , C.H. Wang, 2012, “A novel structure design towards extremely low thermal conductivity for thermal barrier coatings –Experimental and mathematical study,” Materials and design, vol.  35, 2012, pp. 505-517.

[29]  S. Rupangudi, C. Ramesh, and K.V. Veerabhadhrappa, “ Study of Effect of Coating of Piston on the Performance of a Diesel Engine,” SAE International, Paper No. 2014-01-1021, 2014.

[30]  H. Ashouri, B. Beheshti and M.R. Ebrahimzadeh “Analysis of fatigue cracks of diesel engines cylinder heads using a two-layer viscoplasticity model with considering viscosity effects, ” Journal of Simulation & Analysis of Novel Technologies in Mechanical Engineering, Vol  9, 2016, No. 1, 105-120.

[31]  M. Azadi and  G.H. Farrahi, “A new low cycle fatigue lifetime prediction model for magnesium alloy based on modified plastic strain energy approach, ” Journal of Simulation & Analysis of Novel Technologies in Mechanical Engineering, Vol  6, 2013, No. 1, 63-76.

[32]  S. Trampert, T. Göcmez, and F. Quadflieg, “Thermomechanical Fatigue Life Prediction of Cast Iron Cylinder Heads,  ASME Internal Combustion Engine Division 2006 Spring Technical Conference, ” ICES2006-1420, 2006.

[33]  A. Londhe and V. Yadav, “Thermo-structural Strength Analysis for Failure Prediction and Concern Resolution of an Exhaust Manifold,” CAE, R&D, Mahindra and Mahindra Ltd,Automotive Sector, Nasik, India, 2007