Review of Thermal Barrier Coatings for Improving the Performance of Internal Combustion Engines

The literature indicates that YSZ, YPSZ, Mg-PSZ, alumina, mullite, MgO-ZrO₂, SiC and other ceramic materials have been widely investigated as thermal barrier materials for IC-engine components. Most studies have concentrated on the piston crown, although coatings have also been applied to cylinder heads, cylinder liners, valves and piston rings. Plasma spraying remains one of the most frequently reported deposition techniques because it can produce relatively thick ceramic layers with good thermal-insulation characteristics. Across the reviewed investigations, the application of TBCs generally results in higher piston/crown surface temperatures, reduced heat transfer to the piston substrate, improved brake thermal efficiency and reduced specific fuel consumption. Several studies have also reported reductions in HC and CO emissions. However, the increase in combustion-zone temperature can potentially promote NOx formation and increase thermal stresses if the coating thickness and material are not appropriately selected. Therefore, the effectiveness of a TBC system depends strongly on coating material, thickness, bond-coat selection, deposition technique, substrate material, engine operating condition and thermal-stress behaviour. These factors indicate the need for further optimisation and experimental validation before TBCs can be reliably implemented in practical IC-engine applications.

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