Fabrication and analysis of yttria -stabilized zirconia-nickel as thermal barrier coating for automotive turbocharger volute casing
Also available in printed version
| 第一著者: | |
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| その他の著者: | |
| フォーマット: | Doctoral thesis |
| 言語: | 英語 |
| 出版事項: |
Universiti Teknologi Malaysia
2025
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| 主題: | |
| オンライン･アクセス: | https://utmik.utm.my/handle/123456789/51586 |
| Abstract | Abstract here |
| _version_ | 1854975099064549376 |
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| author | Muhammad Rabiu Abbas |
| author2 | Alias Mohd. Noor, supervisor |
| author_facet | Alias Mohd. Noor, supervisor Muhammad Rabiu Abbas |
| author_sort | Muhammad Rabiu Abbas |
| description | Also available in printed version |
| format | Doctoral thesis |
| id | utm-123456789-51586 |
| institution | Universiti Teknologi Malaysia |
| language | English |
| publishDate | 2025 |
| publisher | Universiti Teknologi Malaysia |
| record_format | dspace |
| record_pdf | Abstract |
| spelling | utm-123456789-515862025-08-21T08:44:59Z Fabrication and analysis of yttria -stabilized zirconia-nickel as thermal barrier coating for automotive turbocharger volute casing Muhammad Rabiu Abbas Alias Mohd. Noor, supervisor Mechanical engineering Also available in printed version Turbocharging is a technique commonly used to improve power density, reduce fuel consumption and pollutant emission of internal combustion engines. The high cost and high density of tungsten, which is currently used as the turbine volute casing material, has made the turbocharger costly and heavier. In order to improve its efficiency, thermal barrier coating has been reported as an alternative way for thermal insulation of components operating under high temperature environments. Various type of different coating techniques are available, but the major set-back are high cost and high technical skills requirement. In this work, the thermal properties of nickel alloy substrate was improved through cost effective functionally graded thermal barrier coating (FG-TBC) technique applied on turbocharger turbine volute casing. Simulation input parameters such as thermal conductivity, specific heat capacity and density of the different compositions of the FG-TBC were determined using standard methods. COMSOL multiphysics heat transfer software was also used to predict the heat transfer behaviour on different FG-TBC layers as well as to evaluate their compatibility. The coating slurry was developed using appropriate mixture of yttria-stabilized zirconia (YSZ) and nickel (Ni) powder, distilled water, polyvinyl alcohol and ammonium citrate tribasic. Three different compositional layers of coatings were deposited on the Ni substrate using an automatic film applicator. The adhesion strength of the different coated layers were evaluated using adhesion tester. An in-house fabricated high temperature test rig was used to evaluate the heat resistance capability of the FG-TBC produced. Coating characterizations were conducted before and after the high temperature tests to evaluate the durability, reliability and integrity of the coating. Finally, a GT-power engine performance simulation software was employed to evaluate the on-engine performance of the FG-TBC material when used as a turbocharger turbine volute casing. The results revealed that the composition (wt%) of YSZ:Ni ratio that provide good coating performance for the one, two and three layer(s) were 30:70, 55:45 and 75:25, respectively. The optimum parameters for slurry composition (wt%) were found as 45.5% YSZ:Ni, 51.20% solvent, 3% binder and 0.3% dispersant. The adhesion strength for the one, two and three coated layer(s) were found as 2.63MPa, 3.08MPa and 3.59MPa, respectively. The heat resistance capabilities of different FG-TBC layers at experimental temperature of 750ºC were found as 40ºC, 130ºC and 250ºC for one, two and three coating layer(s) respectively. Average turbine efficiencies of 54.1%, 59.2%, 63.4%, 64.03% and 65.15% were achieved from the simulation at the engine speeds of 1000 rpm, 1500 rpm, 2000 rpm, 2500 rpm and 3000 rpm respectively. Similarly, the compressor efficiency of 55.3%, 62.2%, 65.5%, 67.97% and 68.97% were achieved at the same engine speed fahmimoksen UTM 224 p. Thesis (Ph.D (Kejuruteraan Makanikal)) - Universiti Teknologi Malaysia, 2016 2025-03-14T04:54:40Z 2025-03-14T04:54:40Z 2016 Doctoral thesis https://utmik.utm.my/handle/123456789/51586 vital:106563 valet-20180104-114222 ENG Closed Access UTM Complete Unpublished Completion application/pdf Universiti Teknologi Malaysia |
| spellingShingle | Mechanical engineering Muhammad Rabiu Abbas Fabrication and analysis of yttria -stabilized zirconia-nickel as thermal barrier coating for automotive turbocharger volute casing |
| thesis_level | PhD |
| title | Fabrication and analysis of yttria -stabilized zirconia-nickel as thermal barrier coating for automotive turbocharger volute casing |
| title_full | Fabrication and analysis of yttria -stabilized zirconia-nickel as thermal barrier coating for automotive turbocharger volute casing |
| title_fullStr | Fabrication and analysis of yttria -stabilized zirconia-nickel as thermal barrier coating for automotive turbocharger volute casing |
| title_full_unstemmed | Fabrication and analysis of yttria -stabilized zirconia-nickel as thermal barrier coating for automotive turbocharger volute casing |
| title_short | Fabrication and analysis of yttria -stabilized zirconia-nickel as thermal barrier coating for automotive turbocharger volute casing |
| title_sort | fabrication and analysis of yttria stabilized zirconia nickel as thermal barrier coating for automotive turbocharger volute casing |
| topic | Mechanical engineering |
| url | https://utmik.utm.my/handle/123456789/51586 |
| work_keys_str_mv | AT muhammadrabiuabbas fabricationandanalysisofyttriastabilizedzirconianickelasthermalbarriercoatingforautomotiveturbochargervolutecasing |