Exhaust Heat Management By Ceramic Coatings in Formula one

By,

Akheel AhamedMSc in Mechanical Engineering Hochschule Rheinwaal 1

Design Problem

• Application: Formula 1 Car Engine Exhaust

• Reason: Causes damage by heat transfer to the nearby carbon fiber parts

• Temperature: 1000°C

• Design Requirements : • Light Weight,

• Reduce the temperature to 450°C

• Durable (1200km)

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Material SelectionP

ERFO

RM

AN

CE

MATERIAL

COMPARISON OF MATERIALS

Mild carbon with iron oxide coating aluminized steel Stainless Steel INCONEL with Ceramic Coating

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Exhaust Material

• Material: heat-resistant steel called Inconel

• Inconel also called Alloy 718 contains approx• 60% Nickel

• 22% Chromium

• Traces of Molybdenum and Niobium

• Oxidation and corrosion resistant

• Retains strength over a wide temperature range, over 1000°C.

• Thickness : 1 millimeter

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INCONEL 718 Alloy

http://www.imim.pl/files/archiwum/Vol4_2012/04.pdf 6

• Ceramics are inorganic, non-metallic materials that are processed and used at high temperatures, highly resistant to corrosive compound, resistance to heat and frictions (lasting longer than other materials which occurred by machining.)

• Ceramic coatings are a special film layer used on materials to protect them from wear and tear and to make them resistant to heat.

• Ceramic particles are sub-micron in size and consist of mixtures of selected ceramic materials bonded together and to the substrate.

Ceramics and Ceramic Coating

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Ceramic Coating

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Temprature

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Coating Process

• Done by Plasma Spray Process

• Plasma spraying process involves the latent heat of ionized inert gas (Plasma) being used to create the heat source

• Argon flows between the electrode and nozzle.

• A high frequency or high voltage alternating electric arc is struck between the nozzle and the electrode, which ionizes the gas stream

• Due to the expansion of gas, an increase in the velocity of gas stream.

• Feed stock (material in various powder forms) is injected into the gas stream.

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Advantages

• A robust eliminating the need for exhaust wrap, protecting components against corrosion whilst continuing to perform and look good race after race.

• Significantly lower exhaust surface temperatures (reduce by ~33%.)

• Reduced heat loss from the exhaust resulting in lower engine bay temperatures - reductions of >50oc were recorded by one race team

• Protection for vulnerable components located close to the exhaust; avoiding heat damage, increasing component life, and allowing closer packaging of equipment inside the engine bay.

• Improved engine performance and reliability. Lower air intake temperatures lead to increased engine power, whilst keeping the heat inside the exhaust gas allows the gases to flow more easily increasing cylinder scavenging, and allowing turbochargers to spool up more quickly.

• Reduced heat soak through footwells, bulkheads, etc. So drivers are potentially cooler, more comfortable, and more able to concentrate.

• Rapid cooling of the exhaust when the engine is turned off - the surface temperature of the coating drops quickly when the engine is off, making pit stops faster, easier and safer

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Comparison of Surface Temperature

Uncoated Exhaust System Ceramic coated Exhaust System

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Disadvantages

• Expensive

• Requires Skilled Labour

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Video

https://www.youtube.com/watch?v=KdsAtU3VzAM 14

Summary

• Ceramics counts for a good choice coating on to a heat resistant material for better heat management system in formula one cars.

• The plasma spraying process is expensive but perfectly suitable for ceramic coating.

• Ceramic is not only heat resistant but also corrosion resistant.

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References

• “Thermal barrier coatings characteristics of microstructure and properties, generation and directions of development of bond”, by G. Moskal Department of Materials Science, Silesian University of Technology.

• http://www.nssmc.com/en/tech/report/nsc/pdf/6403.pdf

• http://www.ijrdet.com/files/Volume2Issue3/IJRDET_0314_12.pdf

• http://www.zircotec.com/

• http://www.fst.nl/plasma-spray/

• http://www.tstcoatings.com/plasma_spray.html

• http://www.imim.pl/files/archiwum/Vol4_2012/04.pdf

• http://www.jfe-21st-cf.or.jp/chapter_1/1e_2.html

• https://www.dieselnet.com/tech/diesel_exh_mat.php

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Any Questions?

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Thank You.

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