Thermally insulated engine components using a ceramic coating

Patent metadata

Field	Value
Publication number	US-10995661-B2
Application number	US-201916725533-A
Country	US
Kind code	B2
Filing date	Dec 23, 2019
Priority date	Nov 20, 2015
Publication date	May 4, 2021
Grant date	May 4, 2021

Abstract

A component for exposure to a combustion chamber of a diesel engine and/or exhaust gas, such as a cylinder liner or valve face, is provided. The component includes a thermal barrier coating applied to a body portion formed of steel. A layer of a metal bond material can be applied first, followed by a mixture of the metal bond material and a ceramic material, optionally followed by a layer of the ceramic material. The ceramic material preferably includes at least one of ceria, ceria stabilized zirconia, yttria stabilized zirconia, calcia stabilized zirconia, magnesia stabilized zirconia, and zirconia stabilized by another oxide. The thermal barrier coating is applied by thermal spray or HVOF. The thermal barrier coating has a porosity of 2% by vol. to 25% vol., a thickness of less than 1 mm, and a thermal conductivity of less than 1.00 W/m·K.

First claim

The invention claimed is:

1. A component for exposure to a combustion chamber of an internal combustion engine and/or exhaust gas generated by the internal combustion engine, comprising:
a body portion formed of metal;
a thermal barrier coating applied to said body portion;
said thermal barrier coating including a metal material and a ceramic material;
said ceramic material including ceria stabilized zirconia; and
said thermal barrier coating having a thickness of less than less than 1 mm.

2. The component of claim 1 , wherein said thermal barrier coating has a porosity of 2% by vol. to 25% by vol., based on the total volume of said thermal barrier coating.

3. The component of claim 1 , wherein said ceramic material of said thermal barrier coating further includes at least one of yttria stabilized zirconia, calcia stabilized zirconia, and magnesia stabilized zirconia.

4. The component of claim 1 , wherein said ceramic material consists of ceria stabilized zirconia.

5. The component of claim 1 , wherein said metal material is applied directly to said body portion formed of metal, and 5% to 20% of said thickness of said thermal barrier coating consists of said metal material applied directly to said body portion;
said thermal barrier coating includes a gradient structure applied directly to said metal material, said gradient structure includes metal and said ceramic material, the amount of said ceramic material present in said gradient structure increases continuously toward a top surface of said thermal barrier coating; and
said thermal barrier coating includes a top layer of said ceramic material applied directly to said gradient structure and extending to said top surface, and 5% to 50% of said thickness of said thermal barrier coating consists of said top layer of said ceramic material.

6. The component of claim 1 , wherein said metal material includes at least one alloy selected from the group consisting of CoNiCrAlY, NiCrAlY, NiCr, NiAl, NiCrAl, NiAlMo, and NiTi.

7. The component of claim 1 , wherein a surface of said body portion to which said thermal barrier coating is applied is free of any feature having a radius of less than 0.1 mm.

8. The component of claim 1 , wherein said thermal barrier coating applied to a surface of said body portion has a bond strength of at least 2000 psi when tested according to ASTM C633.

9. The component of claim 1 , wherein said thermal barrier coating is applied to a surface of said body portion exposed to said combustion chamber and/or said exhaust gas, and said thermal barrier coating is applied a first portion of said surface and not applied to a second portion of said surface.

10. The component of claim 1 , wherein said component is selected from the group consisting of a cylinder liner, a cylinder head, a fuel injector, a valve seat, and a valve face.

11. The component of claim 10 , wherein said component is said cylinder liner, said cylinder liner includes an inner diameter surface, and said thermal barrier coating is applied to a first portion of said inner diameter surface located opposite a top land of a piston when the piston is located at top dead center and not applied to a second portion of said inner diameter surface located below said first portion.

12. The component of claim 11 , wherein said inner diameter surface of said cylinder liner includes a groove, and said thermal barrier coating is disposed in said groove.

13. The component of claim 1 , wherein said component is selected from the group consisting of a valvetrain, a surface of a post-combustion chamber, an exhaust manifold, and a turbocharger.

14. The component of claim 1 , wherein at least one additional layer formed of metal is applied to said thermal barrier coating.

15. The component of claim 14 , wherein said metal of said at least one additional layer is the same as said metal material of said thermal barrier coating.

16. The component of claim 1 , wherein said thermal barrier coating has a surface roughness Ra of less than 15 μm and a surface roughness Rz of not greater than 110 μm.

17. A component for exposure to a combustion chamber of an internal combustion engine and/or exhaust gas generated by the internal combustion engine, comprising:
a body portion formed of metal;
a thermal barrier coating applied to said body portion;
said thermal barrier coating including ceria stabilized zirconia;
and
said thermal barrier coating having a surface roughness Ra of less than 15 μm and a surface roughness Rz of not greater than 110 μm.

18. The component of claim 17 , wherein said component is selected from the group consisting of a valvetrain, a surface of a post-combustion chamber, an exhaust manifold, and a turbocharger.

19. A component for exposure to a combustion chamber of an internal combustion engine and/or exhaust gas generated by the internal combustion engine, comprising:
a body portion formed of metal;
a thermal barrier coating applied to said body portion;
said thermal barrier coating including ceria stabilized zirconia;
said thermal barrier coating having a porosity of 2% by vol. to 25% by vol., based on the total volume of said thermal barrier coating.

20. The component of claim 19 , wherein said component is selected from the group consisting of a valvetrain, a surface of a post-combustion chamber, an exhaust manifold, and a turbocharger.

Assignees

• Tenneco Inc

Inventors

• Lineton Warran Boyd
• Azevedo Miguel
• Salenbien Greg

Classifications

• C23C4/073 Primary

  containing MCrAl or MCrAlY alloys, where M is nickel, cobalt or iron, with or without non-metal elements · CPC title

• C23C4/18

  After-treatment · CPC title

• C23C28/3215

  at least one MCrAlX layer · CPC title

• C23C28/3455

  with a refractory ceramic layer, e.g. refractory metal oxide, ZrO2, rare earth oxides or a thermal barrier system comprising at least one refractory oxide layer · CPC title

• C23C4/02

  Pretreatment of the material to be coated, e.g. for coating on selected surface areas · CPC title