Investigations into the degradation mechanism of thermal barrier applied in IC engine

In the present paper the results of investigations into the degradation mechanizm of thermal barrier coating (TBC) applied in spark ignited and naturally aspirated diesel engines are presented. The TBC comprised 0.09 mm thick NiCrAlY bond coat and 0.36 mm thick Al2O3-40%TiO2 top coat. The coating was atmospheric plasma sprayed on piston heads, inlet and outlet valves and engine head. Top coating was heavily damaged in thermal fatigue tests and in exploitation test on spark ignited engine. The mechanism of damage was spalling of the outermost layer of ceramics. Porosity of the ceramic coating increased significantly which made the coating permeable to the products of combustion and thus facilitated corrosion attack on bond layer. Spalling of coating did not increase wear of piston rings and sleeves. X-ray diffraction studies proved high phase stability ofAl2O3-40%TiO2 top coat. Al2Or40%TiO2 APS sprayed coating cannot be considered the alternative top coat to currently used ZrO2-8%Y2O3in engine applications. Thermal barrier coating based on Al2O3-40%TiO2 can not be used for adiabatization of diesel or spark ignited engines. Al2O3-40%TiO2 based TBC can be used in less demanding applications.