Search Results (137)

In the pursuit of zero-emission mobility, hydrogen represents a promising fuel for internal combustion engines. However, its low volumetric energy density poses challenges, especially for high-performance applications where compactness and lightweight design are crucial. This study investigates the feasibility of an innovative hydrogen-fueled two-stroke opposed-piston (2S-OP) engine, targeting a specific power of 130 kW/L and an indicated thermal efficiency above 40%. A detailed 3D-CFD analysis is conducted to evaluate mixture formation, combustion behavior, abnormal combustion and water injection as a mitigation strategy. Innovative ring-shaped multi-point injection systems with several designs are tested, demonstrating the impact of injector channels’ orientation on the final mixture distribution. The combustion analysis shows that a dual-spark configuration ensures faster combustion compared to a single-spark system, with a 27.5% reduction in 10% to 90% combustion duration. Pre-ignition is identified as the main limiting factor, strongly linked to mixture stratification and high temperatures. To suppress it, water injection is proposed. A 55% evaporation efficiency of the water mass injected lowers the in-cylinder temperature and delays pre-ignition onset. Overall, the study provides key design guidelines for future high-performance hydrogen-fueled 2S-OP engines. Full article

Atmospheric plasma spraying was used to create composite coatings employing mixed alloy matrices supplemented with carbon-based solid lubricants as feedstock materials. The current study’s goal was to examine the tribological properties of these coatings and explore the potential benefits of using CNTs as a nano-additive to minimize wear and friction while enhancing lubrication conditions in tribosystems such as piston ring–cylinder liner systems. Pin-on-disk measurements are used to correlate the chemical composition of feedstock materials with the friction coefficient and wear rate during coating operation. The enhanced behavior of the produced coatings is investigated. The anti-wear performance of Co-based cermet and metal alloys coatings, as well as the enhanced lubrication conditions during operation, are shown. In-depth discussion is provided regarding how the features of the feedstock powder affect the quality and performance of the produced coatings. The results showed that coatings based on the CoMo alloy exhibited an increase in wear due to CNT agglomeration. In contrast, CNT addition led to an improvement in bonding strength by up to 33%, a reduction in wear rate by up to 80%, and a decrease in the coefficient of friction from approximately 0.70 to 0.35 in CoNi cermet coatings. These findings demonstrate the role of CNTs in coating performance for demanding tribological applications. Full article

Advanced engineering materials are in high demand for a combination of tailored properties in a single material. Titanium with aluminum alloys is widely used to prepare pistons and knee joints due to its high strength and abundant availability. The primary focus of the study was to utilize an eco-friendly composite material with low cost and a simple production process. Ti–48Al–2Cr–2Nb with molybdenum disulfide was added as reinforcement in varying percentages, fabricated using the squeeze casting production technique. The dry sliding wear test was performed. Adding 4% molybdenum disulfide to Ti–48Al–2Cr–2Nb enhanced its mechanical properties and wear resistance by 57%. Full article

This study presents a comprehensive evaluation of the tribological behavior of cylinder liners and piston rings—key components in internal combustion engines (ICEs). Experiments were conducted using a pin-on-disc wear tester under varying loads (50–100 N) and speeds (175–350 rpm) to determine the coefficient of friction (μ) and wear rate. The selected pin and disc materials represent real engine components to ensure realistic operating conditions. Before and after each experiment, the cylinder liner-piston ring pair was cleaned with acetone to ensure accurate measurement of mass loss. Surface roughness (Ra, Rq, Rz, µm) was assessed using a Mahr M-1 profilometer, and Brinell hardness tests were carried out using a digital optical Brinell hardness testing machine to determine the mechanical properties of the contact surfaces. The results revealed that safflower oil achieved the lowest coefficient of friction at higher speeds, with an 18% reduction compared with conventional 20W-50 engine oil. Camelina oil, camelina biodiesel and safflower biodiesel each exhibited a reduction of approximately 12.5% in friction, highlighting their potential as viable alternatives to petroleum-based lubricants. Full article

Improving the thermal efficiency of internal combustion engines plays a crucial role in reducing fuel consumption and engine emissions. Studies have shown that the friction loss caused by the piston ring–cylinder liner pair accounts for approximately 30–40% of the engine’s total mechanical friction. The key to improving mechanical and thermal efficiency lies in reducing frictional losses through advanced solutions. However, as engine intensification increases, the growing thermal and mechanical loads lead to out-of-round deformation of the cylinder liner. This deformation reduces the sealing conformity of the piston rings, leading to increased blow-by and elevated particulate matter (PM) emissions. To address this, a dynamic–static deformation testing system for cylinder liners, combined with a multi-physics simulation for data validation, has been developed to achieve energy conservation and emission reduction in engines. Based on established strain gauge and eddy current displacement sensors, this study developed a dynamic deformation testing system, modified for a specific type of diesel engine, and analyzed the cylinder liner deformation under fired conditions. Test results show that under engine speeds ranging from 700 rpm to 1100 rpm, the overall radial out-of-roundness of the cylinder liner increased, with a maximum deformation of 49.2 μm. The second-order component of out-of-roundness also increases with speed, showing a maximum rise of 28.9 μm, while the third-order and fourth-order components exhibit relatively minor changes. These findings suggest that the overall radial deformation under fired conditions is mainly dominated by second-order out-of-roundness, with third-order and fourth-order components contributing marginally. Full article

With the implementation of the ISO 8217-2024 marine fuel standard, the use of high-concentration biofuels in ships has become viable. However, relatively few studies have been conducted on the effects of biofuels on cylinder lubrication performance in low-speed, two-stroke marine diesel engines. In this study, catering waste oil was blended with 180 cSt low-sulfur fuel oil (LSFO) to prepare biofuels with volume fractions of 24% (B24) and 50% (B50). These biofuels were evaluated in a MAN marine diesel engine under load conditions of 25%, 50%, 75%, and 90%. The experimental results showed that, at the same engine load, the use of B50 biofuel led to lower kinematic viscosity and oxidation degree of the cylinder residual oil, but higher total base number (TBN), nitration level, PQ index, and concentrations of wear elements (Fe, Cu, Cr, Mo). These results indicate that the wear of the cylinder liner–piston ring interface was more severe when using B50 biofuel than when using B24 biofuel. For the same type of fuel, as the engine load increased, the kinematic viscosity and TBN of the residual oil decreased, while the PQ index and the concentrations of Fe, Cu, Cr, and Mo increased, reflecting the aggravated wear severity. Ferrographic analysis further revealed that ferromagnetic wear particles in the oil mainly consisted of normal wear debris. When using B50 biodiesel, a small amount of fatigue wear particles were detected. These findings offer crucial insights for optimizing biofuel utilization and improving cylinder lubrication systems in marine engines. Full article

Improving the reliability and durability of internal combustion engines in marine vessels is a complex issue. The vibrations generated in these engines significantly affect their proper operation. One of the current research challenges is identifying effective methods to reduce, among other things, torsional vibrations generated within the crank–piston system. To mitigate these vibrations, viscous dampers are commonly used. The selection of a viscous damper for a high-power multi-cylinder engine, such as those in marine power plants, requires a thorough understanding of the thermo-hydrodynamic properties of oil films formed in the spaces between the damper housing and the inertial mass. The description of the phenomena involved is complicated by the variable positioning of the inertial mass center relative to the housing during operation. Most previous studies assume a concentric alignment between these components. The main novelty of this work lies in highlighting the combined effect of the eccentric motion of the inertial ring on both hydrodynamic resistance and thermal characteristics, which has not been fully addressed in existing studies. This article defines the oil flow resistance coefficients and develops static characteristics of the dampers. Additionally, it evaluates the impact of the size of the frontal and cylindrical surfaces of the damper on its heat dissipation capacity. The presented characteristics can be utilized to assess the performance parameters of this type of damper. Full article

The lubrication performance of the cylinder liner–piston ring (CLPR) is crucial for the energy efficiency and operating reliability of marine diesel engines. To enhance the boundary lubrication of marine engine oil, a 1,3-diketone fluid HPTD (1-(4-hexylphenyl) tridecane-1,3-dione, HPTD) was introduced as an ash-free friction modifier. Besides that, octadecylamine-functionalized nanocopper particles (ODA-Cu) were also added to the marine oil to improve its anti-wear behavior. Through cylinder-on-disk friction tests, the appropriate contents of HPTD and ODA-Cu were determined, which then formed hybrid additives and modified the engine oil. The tribological performance of the modified oil was analyzed under various normal loads, reciprocating frequencies, and testing temperatures. Based on the synergy of the tribochemical reaction of HPTD and the mending effect of ODA-Cu on the sliding surface, the modified oil not only had lower sulfated ash content but also exhibited superior lubrication performance (i.e., reduced coefficient of friction by 15%, smaller wear track by 43%, and higher maximum non-seizure load by 11%) than the pristine engine oil. The results of this study would be helpful for the design of novel hybrid eco-friendly additives for marine engine oil. Full article

The use of combustion engines on agricultural vehicles will persist much longer than on-road vehicles. Introducing new technologies in agricultural engines is crucial to mitigating emissions while accounting for customer cost-sensitivity, harsh operation conditions, and typically sub-optimal maintenance. This work describes the use of CrN and tetrahedral amorphous carbon (ta-C) DLC-coated rings in small agricultural diesel engines. Compared with the gas nitride rings, the CrN and the ta-C DLC coatings exhibited, respectively, 74% and 86% lower wear in rig tests. The DLC also presented a very low coefficient of friction and high resistance to scuffing. A similar wear trend was observed on durability engine tests, where the CrN top ring showed an 80% lower wear rate than the GNS used in a similar engine. Wear on the DLC oil ring was below the measurement capability. Liner radial wear was measured on the piston ring reversal points in four angular positions, and except for one position, was lower than 3 µm. At the end of the test, engine performance and emissions are nearly identical to those at the test’s start, demonstrating that the use of advanced tribological solutions can significantly contribute to emissions mitigation in agricultural engines. Full article

Piston ring–cylinder liner is one of the most important friction pairs in internal combustion engines. The surfaces of the piston ring and the cylinder liner are affected by high temperature and high pressure, and the influence mechanism of temperature and pressure on their microscopic morphology parameters is yet to be revealed. In this paper, high temperature friction and wear experiments on the piston ring and cylinder liner are carried out to obtain the microscopic morphology of the cylinder liner and piston ring at different temperatures and pressures, and their changes under different temperatures and pressures are investigated by using two methods, namely, fractal dimension and three-dimensional surface roughness characterization. The results show that, as the temperature increases, the texture patterns on the cylinder liner’s friction surface become simpler, with the fractal dimension showing a decreasing trend while the roughness shows an increasing trend. Compared to the condition at 80 °C, the surface roughness (Sa) of the cylinder liner increased by approximately 58.43% at 190 °C, while that of the piston ring increased by about 96.5%. With increasing pressure, both the fractal dimension and the roughness of the friction surface first decrease and then increase. Full article

High-temperature fretting wear typically occurs on mechanical contact surfaces in high-temperature environments, with displacement amplitudes generally in the micrometer range (≤300 μm), such as the turbine disks and blades in aerospace engines, and the piston rings in automotive engines. The study performed tangential fretting wear tests between superalloy specimens and Si₃N₄ balls under 700 °C to investigate the influence of ground and milled surface morphologies on the high-temperature fretting wear behavior. The experimental results show distinct wear mechanisms for the two surface types: ground specimens exhibit adhesive and oxidative wear, while milled specimens experience fatigue and abrasive wear. Both wear modes intensify with increasing load and fretting frequency. A comprehensive surface morphology characterization method, combining fractal dimension (FD) and surface roughness, is proposed. The study reveals that the roughness parameters Sa and Ra are strongly correlated with the Coefficient of Friction, while FD is strongly correlated with the wear volume. This study provides a novel approach to characterizing the evolution of surface morphology during high-temperature fretting wear. Full article

This experimental study investigates the critical role and impact of additive concentration in enhancing the tribological performance of castor oil as a biolubricant for agricultural tractor engines. Friction and wear are major contributors to reduced engine efficiency, highlighting the need for effective lubrication strategies. While biolubricants like castor oil offer environmental benefits, they often require additives to achieve optimal performance. However, the concentration of these additives is crucial, as an imbalance can negatively impact the lubrication system, leading to a higher coefficient of friction, increased wear, and reduced engine efficiency and lifespan. This study examines the effects of varying concentrations of a mixture of propyl gallate (PG) and ionic liquid (IL) additives on the tribological performance of castor oil. The tribological behaviour of lubricated top compression piston ring and cylinder liner samples was evaluated under simulated engine conditions using a Bruker UMT Tribolab test rig, in accordance with the ASTM G181 standard. The experimental results revealed an influence of additive concentration on the coefficient of friction and wear behaviour. This emphasises the importance of optimising additive formulations to minimise engine wear and friction. Notably, a 0.5% volume concentration of the additive mixture led to a remarkable 34.8% reduction in the average coefficient of friction (COF) and a lower wear rate. Full article

In this work, 1,3-diketone synthesized via the Claisen condensation method and nano-copper particles modified by the Brust–Schiffrin method were added into a commercial marine medium-speed diesel engine cylinder piston oil to evaluate their effects on boundary lubrication performance. Friction and wear tests conducted on CKS-coated piston ring and cast-iron cylinder liner samples demonstrated significant reductions in both friction and wear with the addition of 1,3-diketone and nano-copper particles. Compared to the original oil without additives, the friction force was reduced by up to 16.7%, while the wear of the piston ring and cylinder liner was decreased by up to 21.6% and 15.1% at 150 °C, respectively. A worn surface analysis indicated that the addition of 1,3-diketone and functionalized nano-copper particles influenced the depolymerization and tribo-chemical reactions of the anti-wear additive ZDDP (zinc dialkyldithiophosphate) in the original engine oil. This modification enhanced the oil’s anti-friction and anti-wear properties, offering valuable insights into the development of eco-friendly lubricants for energy-efficient systems. Full article

Friction and wear reduction in internal combustion engines are crucial for improving efficiency and durability. This study investigates the effect of microtextured surfaces on friction power loss in an engine’s piston ring-cylinder system. A numerical analysis was conducted on piston rings equipped with dimple-shaped microtextures using AVL Excite Piston & Rings, modelling a hard chromium-coated piston ring and a cast iron cylinder. The goal was to determine the optimal surface texture parameters that minimize friction power loss under typical urban driving conditions with SAE 0W-30 oil. A two-step Design of Experiments (DoE) approach was employed, where the first step involved mapping the effects of texture parameters, i.e., dimple depth (A = 0.5, 1, 1.5 µm), dimple distance (B = 120, 160, 240 µm), and dimple diameter (C = 50, 60, 70 µm), to identify influential factors. The second step aimed at locating a parameter configuration with minimal friction power loss. The results demonstrated that the optimized texture parameters can significantly reduce friction power loss. The lowest friction power loss of 8.96 W was achieved with a dimple depth of 2 µm, distance of 80 µm, and diameter of 60 µm, which contributed to an 8.3% improvement over the reference surface. The model built to describe the investigated texturing approach exhibited a strong correlation with an R² value of 0.93, and the deviation between predicted and measured values was below 1%. Future work will involve tribometer tests to experimentally validate the optimized parameters and confirm the simulation results. Full article

With the global shift in energy structure and the advancement of the “double carbon” strategy, methanol has gained attention as a clean low-carbon fuel in the engine sector. However, the corrosion–wear coupling failure caused by acidic byproducts, such as methanoic acid and formaldehyde, generated during combustion severely limits the durability of methanol engines. In this study, we employed a systematic approach combining the construction of a corrosion liquid concentration gradient experiment with a full-load and full-speed bench test to elucidate the synergistic corrosion–wear mechanism of core friction pairs (cylinder liner, piston, and piston ring) in methanol-fueled engines. The experiment employed corrosion-resistant gray cast iron (CRGCI), high chromium cast iron (HCCI), and nodular cast iron (NCI) cylinder liners, along with F38MnVS steel and ZL109 aluminum alloy pistons. Piston rings with DLC, PVD, and CKS coatings were also tested. Corrosion kinetic analysis was conducted in a formaldehyde/methanoic acid gradient corrosion solution, with a concentration range of 0.5–2.5% for formaldehyde and 0.01–0.10% for methanoic acid, simulating the combustion products of methanol. The results showed that the corrosion depth of CRGCI was the lowest in low-concentration corrosion solutions, measuring 0.042 and 0.055 μm. The presence of microalloyed Cr/Sn/Cu within its pearlite matrix, along with the directional distribution of flake graphite, effectively inhibited the micro-cell effect. In high-concentration corrosion solutions (#3), HCCI reduced the corrosion depth by 60.7%, resulting in a measurement of 0.232 μm, attributed to the dynamic reconstruction of the Cr₂O₃-Fe₂O₃ composite passive film. Conversely, galvanic action between spherical graphite and the surrounding matrix caused significant corrosion in NCI, with a depth reaching 1.241 μm. The DLC piston coating obstructed the permeation pathway of formate ions due to its amorphous carbon structure. In corrosion solution #3, the recorded weight loss was 0.982 mg, which accounted for only 11.7% of the weight loss observed with the CKS piston coating. Following a 1500 h bench test, the combination of the HCCI cylinder liner and DLC-coated piston ring significantly reduced the wear depth. The average wear amounts at the top and bottom dead centers were 5.537 and 1.337 μm, respectively, representing a reduction of 67.7% compared with CRGCI, where the wear amounts were 17.152 and 4.244 μm. This research confirmed that the HCCI ferrite–Cr carbide matrix eliminated electrochemical heterogeneity, while the DLC piston coating inhibited abrasive wear. Together, these components reduced the wear amount at the top dead center on the push side by 80.1%. Furthermore, mismatches between the thermal expansion coefficients of the F38MnVS steel piston (12–14 × 10⁻⁶/°C) and gray cast iron (11 × 10⁻⁶/°C) resulted in a tolerance exceeding 0.105 mm in the cylinder fitting gap after 3500 h of testing. Notably, the combination of a HCCI matrix and DLC coating successfully maintained the gap within the required range of 50–95 μm. Full article