K. MURUGAN, R. THIRUMALAI: EXPERIMENTAL ANALYSIS OF THE THERMAL-BARRIER COATING ...
121–126
EXPERIMENTAL ANALYSIS OF THE THERMAL-BARRIER
COATING FOR AN Al
2
O
3
-TiO
2
CERAMIC COATED CI ENGINE
OPERATING ON CALOPHYLLUM INOPHYLLUM OIL
EKSPERIMENTALNA ANALIZA KERAMI^NE PREVLEKE NA
OSNOVI Al
2
O
3
-TiO
2
, KI DELUJE KOT TERMI^NA BARIERA V
ZGOREVALNI KOMORI BIODIZELSKEGA MOTORJA
Murugan Kuppusamy
1*
, Thirumalai Ramanathan
2
1
Department of Automobile Engineering, Mahendra Institute of Technology, Namakkal, Tamil Nadu 637503, India
2
Department of Mechanical Engineering, Dr. N. G. P. Institute of Technology, Coimbatore, Tamil Nadu 641048, India
Prejem rokopisa – received: 2020-08-02; sprejem za objavo – accepted for publication: 2020-10-26
doi:10.17222/mit.2020.148
This work focuses on the thermal barrier coating (TBC) with a thickness of 300 μm for the combustion chamber of a single-cyl-
inder four-stroke diesel engine. The piston crown, and inlet and exhaust-valve head are coated using the air-plasma-spray coat-
ing technique. Records found in the available literature revealed that the use of aluminum oxide titanium dioxide (Al2O3-TiO2)
ceramic-powder coating and punnagam oil methyl ester (POME) is the most preferred method for improving emission levels.
Punnagam oil methyl ester (POME) was prepared with transesterification in order to blend the same substances with biodiesel
proportions of B25, B50, B75, B100 and conventional diesel. The proposed test report relies on a single-cylinder four-stroke
diesel engine without any modification. This research is aimed at reducing the emission levels and attaining a greener and
cleaner system by using a renewable fuel. The test was carried out to assess the engine performance, viz., the brake power, brake
thermal efficiency, volumetric efficiency, brake specific fuel consumption and air-fuel ratio, assess the emission levels when
combining POME and the Al2O3-TiO2 coated engine and compare them with those of conventional diesel. The amounts of pol-
lutants such as unburned hydrocarbon (HC), carbon monoxide (CO), oxide of nitrogen (NOx) and the emitted smoke opacity
were compared to those produced by conventional diesel. The result revealed that POME and the Al2O3-TiO2 ceramic improved
the performance of the engine so that the pollution levels are much better than those produced by conventional diesel.
Keywords: punnagam oil methyl ester, thermal-barrier coating, air-plasma-spray coating technique, aluminum oxide titanium di-
oxide, ceramic powder material, performance, engine emission
V ~lanku sta se avtorja osredoto~ila na opis za{~itne plasti, ki deluje kot termi~na bariera debeline 300 μm v eno-valjnem
{tiri-taktnem motorju. Povr{ine oz. krona bata, glav sesalnega in izpu{nega ventila, so bile prevle~ene s postopkom
zra~no-plazmskega napr{evanja. V literaturi obstajajo dokazi, da je uporaba kerami~nega prahu na osnovi Al2O3-TiO2 za
izdelavo prevlek vitalnih delov dizelskega motorja, ki deluje na bio-olje metilnega estra (POME; angl.: Punnagam oil methyl es-
ter) najbolj{a metoda za preverjanje emisije izpu{nih plinov. POME so pripravili s procesom trans-esterifikacije, da bi dobili
me{anico, ki odgovarjajo razmerjem B25, B50, B75, B100, med bio- in konvencionalnim dizlom. Predlagani testi so se nana{ali
na eno-cilindri~ni {tiri-taktni dizelski motor brez kakr{nihkoli modifikacij. Ta postopek so izvedli z namenom zmanj{anja
nivojev emisij z uporabo ~istej{ega motorja na obnovljivo gorivo. Preizkuse so izvedli, da bi ugotovili lastnosti motorja glede na
mo~ zaviranja, termi~no u~inkovitost zavor, volumetri~no u~inkovitost, specifi~no porabo med zaviranjem, razmerje gorivo-zrak
in oceno nivoja emisij kombinacije POME- in Al2O3-TiO2-prevlek v primerjavi s konvencionalnim dizelskim motorjem. Izvedli
so primerjavo emisij onesna`evalcev okolja, kot so: nezgoreli ogljikovodiki (HC), ogljikov monoksid (CO), du{ikovi oksidi
(NOx) in trdni delci (saje). Rezultati testov so pokazali, da kombinacija POME in Al2O3-TiO2 kerami~na prevleka vitalnih delov
motorja izbolj{a lastnosti delovanja izbranega motorja in tudi ugotovljeni nivo emisij onesna`evalcev okolja je bil mnogo manj{i
kot jih je imel uporabljeni konvencionalni dizelski motor.
Klju~ne besede: olje metilnega estra Punnagam, kerami~na prevleka, termi~na bariera, tehnika zra~no-plazemskega napr{evanja,
kerami~na Al2O3-TiO2 prevleka, lastnosti in emisija dizelskega motorja
1 INTRODUCTION
R. Prasad et al.
1
compared the performance of a
TBC-coated engine and an engine without any coatings.
It was observed that the TBC-coated engine reduced heat
losses by 6 % due to the coating of the piston and cylin-
der walls. D. Assanis et al.
2
implemented the effects of
ceramic coatings on a diesel engine, providing a much
better thermal efficiency, lower levels of CO, unburned
HC and the NOx concentration and also reduced smoke
emissions into the coated engine. B. Kamanna et al.
3
used a finite-element analysis to redesign the piston
crown, therefore improving the mechanical efficiency of
a diesel engine. T. Hejwowski et al.
4
studied the effect of
thermal-barrier coatings, reducing the fuel consumption
and improving the engine efficiency effectively. The en-
gine-combustion chamber surface, piston crown, head of
the cylinder, inlet and exhaust valves were coated with a
base coating of NiCrAl and top coating of CaZrO
3
and
MgZrO
3
using plasma-spray coating. The coated engine
was evaluated with respect to the reduction of particulate
emissions from the engine, such as CO, HC. A. Uzun et
Materiali in tehnologije / Materials and technology 55 (2021) 1, 121–126 121
UDK 620.1:669.715:549.514.6:621.313.13 ISSN 1580-2949
Original scientific article/Izvirni znanstveni ~lanek MTAEC9, 55(1)121(2021)
*Corresponding author's e-mail:
muruganauto@gmail.com (Murugan Kuppusamy)

al.
5
described that the thermal-barrier coating is able to
eliminate visible smoke and reduce the NOx emission.
The thermal-fatigue resistance of two TBC layers was in-
vestigated by T. Hejwowski et al.
6
and it was concluded
that this mechanism improves the spallation from coated
diesel and petrol engines. Kumara and Pandey
7
examined
the wear characteristics for the air-plasma spray depos-
ited on the CoNiCrAlY inner metallic coating on an alu-
minum-alloy substrate. The wear characteristics and
microstructure properties obtained with the
air-plasma-spray technique used for the CoNiCrAlY
coating increase the sliding distance and reduce the wear
rate of the CoNiCrAlY coating. The thermal-barrier
coating can prevent a low oxygen-diffusion rate, low
thermal conductivity and improve mechanical properties.
S. Deng et al.
8
prepared coatings with a bond-coat thick-
ness of 6-8 μm, an Al
2
O
3
composite, and a top-coat
thickness of 120 μm, La
2
Zr
2
O
7
. In the TBC on a diesel
engine, a rich-mixture region leads to good performance
of the thermal-barrier coating due to a higher tempera-
ture to surface volume ratio. M. Yao et al.
9
concluded
that there would be improvement in the thermal effi-
ciency because of the TBC. The heat-transfer losses of
the thermal-barrier-coating engine emissions and com-
bustion are also discussed. The thermal behavior of an
electrolytic jet plasma oxidation (EJPO) coating was an-
alyzed with a finite-element analysis, confirming that it
provides improved thermal behavior of IC engines
coated with electronic jet plasma oxidation. X. Shen et
al.
10
concluded that the thermal conductivity improves
because of the coating thickness and that this also im-
proves the wear resistance. The emission reduction of a
thermal-barrier-coated engine using a single blend ratio
of various non-edible oils, cashew-nut shell, orange and
neem oil via a transesterification process can change the
performance of biodiesel. An engine coated with par-
tially stabilized zirconia acting as the thermal barrier
coating is used. V. Karthickeyan et al.
11
focused on the
alternative BTE fuel battery, BSFC, engine emissions
HC, CO and NOx, as compared to the conventional die-
sel. In his study, H. K. Suh et al.
12
investigated the nozzle
geometry and cavitation characteristics of diesel and
biodiesel fuel. It was found that the biodiesel rate of flow
velocity is constant and that diesel fuel increases with
the flow rate. The performance parameters of engines us-
ing thumba biodiesel/diesel blends were analyzed by ap-
plying the Taguchi method and gray relational analysis.
A. Karnwal et al.
12
concluded that the maximum perfor-
mance and minimum emission were found with a CR of
14, nozzle pressure of 250 bar and injection timing of
20°. The usage of biodiesel/diesel blended fuel in a com-
mon-rail DI-diesel engine proved that a higher biodiesel
content causes a low engine power output. G. R. Kanna
et al.
14
predicted the fuel-injection pressure and fuel-in-
jection time for the conversion of palm oil into biodiesel
with an artificial neural network. The benefits of the
thermal-barrier coating were discussed by Selvam et
al.
15
. It was found that when the TBC amount is large, it
provides for a high level of thermal fatigue and heat-re-
lease rate within a yattria-stabilized zirconia-insulated
engine.
2 SELECTION OF THE THERMAL-BARRIER-
COATING MATERIAL
The objective of the study is to demonstrate that ap-
plying a thin layer of a thermal-barrier coating on a pis-
ton head and valve heads can improve the heat energy. A
thick coating can withstand high heat energy, changing it
into low heat energy. A thermal barrier coated with the
(Al
2
O
3
-TiO
2
) ceramic material with a thickness of 300
μm is used by employing the air-plasma-spray coating
technique. The thermal-barrier coating is successfully
used for the piston-head inlet and exhaust-valve head
when it has a thickness of 300 μm. The most universal
TBC is used for yattria-stabilized zirconium
(ZrO
2
/Y
2
O
3
), which is widely believed to improve the
performance of a turbine blade at a temperature of
1100 °C. The plasma-spray technique is used in various
industrial applications where high wear resistance and
corrosion resistance with a thermal insulation are neces-
sary to generate sustainable heat energy. The findings
from the literature reveal that various types of
Al
2
O
3
–TiO
2
plasma-sprayed coatings with different com-
positions (Al
2
O
3
–13 w/% TiO
2
,Al
2
O
3
–40 w/% TiO
2
and
Al
2
O
3
–50 w/% TiO
2
) can be prepared for AISI 304L
austenitic stainless-steel substrate materials.
The physical and chemical properties of an aluminum
oxide titanium dioxide ceramic material (Al
2
O
3
-TiO
2
)
has the potential to withstand the wear and tear, exhibit-
ing high hardness, low coefficient of friction, high ionic
conductivity, high melting point and low thermal con-
ductivity, which make it into a superior engineering ma-
terial. Figure 1 illustrates the air-plasma-spray coating
used to coat the piston head and inlet and exhaust valve
heads using an aluminum oxide titanium dioxide ceramic
material (Al
2
O
3
-TiO
2
) for a modified TVI kirloskar en-
gine. A CNC horizontal milling machine is used for ma-
chining the piston crown and valve heads and after the
machining, the components are coated with an air-
plasma-spray coating (APS) with a thickness of 300 μm.
The coating material consists of a highly reactive ce-
ramic powder with low thermal expansion, low thermal
conductivity, high thermal-shock resistance and high
toughness; the chemical composition of the coating is
Al
2
O
3
=8 7% ,T i O
2
= 9.5–13.5 %, SiO
2
= 0.5 % and
MgO=3%.
3 SELECTION OF ALTERNATIVE FUEL
This study was carried out in four phases. In the first
phase, punnagam oil methyl ester (POME) was prepared
using transesterification. In the second phase, blended
biodiesel prepared from a mixture of different categories
K. MURUGAN, R. THIRUMALAI: EXPERIMENTAL ANALYSIS OF THE THERMAL-BARRIER COATING ...
122 Materiali in tehnologije / Materials and technology 55 (2021) 1, 121–126

including B25, B50, B75, B100 and normal diesel was
used. In the third phase, the thermal-barrier coating was
applied to obtain good heat energy and withstand the
heat during a test of the (Al
2
O
3
-TiO
2
) ceramic material,
using the air-plasma-spray coating technique. The final
phase included an experiment carried out on a single-cyl-
inder four-stroke direct-injection (Al
2
O
3
-TiO
2
)m a t e -
rial-coated engine. The test was carried out to assess the
engine performance and emission characteristics. Vehi-
cles like trucks, buses, cars, trains and airplanes release
an enormous amount of pollution, irreversibly affecting
the air quality. Hence, finding and developing an alterna-
tive fuel have become inevitable. An alternative fuel can
overcome this problem. It can be made of non-edible
vegetable oil and animal fat. Vegetable oil can cause an
injection problem because of its high viscosity and poor
volatility leading to engine deposits, filter gumming and
piston-ring jamming. However, an alternative fuel helps
surmount these problems. Hence, the objective of the
study is to create an alternative fuel that will control the
increasingly high emission levels of the pollutants that
affect the air quality.
The calophyllum inophyllum seed oil (known widely
in Tamil as the punnagam oil) is used in this experiment.
The punnagam-seed oil is non-edible and cultivated in
the vast expanse of East Africa, Malaysia, Australia and
southern Coastal India. The tree is grown extensively in
Maharashtra, the coastal area of Tamil Nadu and
Andamans. It has low hanging branches and takes a long
time to grow. Its height is normally 8–20 m, its leaf is of
an elliptical shape. The fruit is a round green drupe. The
seeds are obtained twice per year, April to June and Oc-
tober to December and an annual yield of these seeds is
20–100 kg/tree. Punnagam seeds, as shown in Figure 2,
can be extracted by removing the outer shell. They have
to be dried in the sun and crushed; later, oil is extracted
from crushed punnagam seed. This process leads to a
hitherto unknown alternative, a non-conventional fuel in-
volving punnagam seeds. These are first dehusked and
converted into punnagam oil methyl ester (POME)
through a transesterification process. It exhibits superior
diesel properties and can be used in a diesel engine.
4 EXPERIMENTAL SET-UP
Figure 3 represents the experimental set-up, which
uses a kirloskar engine. The engine is a single-cylinder
diesel-engine with a bore of 87.5 mm, a stroke of 110
K. MURUGAN, R. THIRUMALAI: EXPERIMENTAL ANALYSIS OF THE THERMAL-BARRIER COATING ...
Materiali in tehnologije / Materials and technology 55 (2021) 1, 121–126 123
Figure 1: Plasma-spray coating
Figure 2: Punnagam tree and seeds

mm and a compression ratio of 17.5:1. The rated power
is 5.2 kw @ 1500 min
–1
. Tests were carried out at 1500
min
–1
at full load. The diesel engine was connected to the
eddy-current dynamometer for loading. The set-up con-
sists of a fuel tank, stand-alone panel box consisting of
an air box, fuel measuring unit, manometer, transmitters
for air and fuel-flow measurements, process indicator
and engine indicator. Rota-meters are provided for water
cooling and a calorimeter is used for water-flow mea-
surements. AVL DiGas 444 is used to measure the emis-
sion parameters like CO, HC, CO
2
,O
2
and NOx while an
AVL 437C smoke meter is used to measure the ex-
haust-smoke opacity.
5. RESULTS AND DISCUSSION
The results depicted below reveal the engine perfor-
mance and emission levels. The current result is an out-
come of a comparison of a conventional engine with a
diesel and transesterified biodiesel (POME) engine
coated with the (Al
2
O
3
-TiO
2
) ceramic. The engine was
tested at a constant speed of 1500 min-1 under a no-load
condition and for 25, 50, 75, 100 biodiesel percentage.
The test was carried out to assess the engine performance
regarding the brake power, brake thermal efficiency, vol-
umetric efficiency, air-fuel ratio and specific fuel con-
sumption. In the next phase engine-emission characteris-
tics regarding unburned hydro carbon, carbon monoxide,
nitrous oxide, and engine-smoke opacity were tested.
5.1 Engine performance parameters
5.1.1 Brake power versus brake thermal efficiency
Figure 4 presents the brake power and brake thermal
efficiency. The brake thermal efficiency is compared
against the Al
2
O
3
-TiO
2
coated conventional-diesel engine
and Al
2
O
3
-TiO
2
coated POME engine. The engine exhib-
its low thermal conductivity, thereby improving the oper-
ation at a high temperature and reducing the ignition de-
lay caused by physical and chemical reactions in the
combustion chamber. A careful scrutiny of the brake
thermal efficiency shows that the blend (POME)
(Al
2
O
3
-TiO
2
) coated engine performed much better. The
break thermal efficiency of the coated, blend (POME)
engine (MP with B75) exhibits an improved performance
compared with the diesel engine.
5.1.2 Brake power versus volumetric efficiency
The experimental result for the volumetric efficiency
depends upon the operating conditions and atmospheric
condition of the operating engine. Figure 5 presents a
comparison of the levels of the volumetric efficiency
against several conditions. It is observed that the use of
the blend (POME) leads to a good atomization, thereby
improving the complete combustion of exhaust gases.
Also, the conventional diesel and the blend (POME) are
better for the modified piston engine operating under full
operating conditions.
5.1.3 Brake power versus brake specific fuel
consumption
The increase in the brake specific fuel consumption
(BSFC) shown in Figure 6 illustrates the variation in the
brake power versus the BSFC for biodiesel, also known
as the brake specific energy consumption (BSEC). The
mean effective pressure of the (Al
2
O
3
-TiO
2
) coated en-
gine is high for the modified piston using B75 when
comparing the blended (POME) and conventional diesel.
The BSFC, also known as the brake specific energy con-
sumption (BSEC), is independent of the blend (POME),
(Al
2
O
3
-TiO
2
) insulated engine.
K. MURUGAN, R. THIRUMALAI: EXPERIMENTAL ANALYSIS OF THE THERMAL-BARRIER COATING ...
124 Materiali in tehnologije / Materials and technology 55 (2021) 1, 121–126
Figure 3: Schematic layout of the experimental set-up
Figure 5: Brake power versus volumetric efficiency
Figure 4: Brake power versus brake thermal efficiency

5.1.4 Brake power versus air-fuel ratio
Figure 7 shows the variation in the brake power ver-
sus the air-fuel ratio. The air-fuel ratio is the most impor-
tant parameter of an IC engine as it is gradually reduced
at all loads when compared to the blend (POME)
(Al
2
O
3
-TiO
2
) insulated engine. The result reveals that
POME is minimum when used with an (Al
2
O
3
-TiO
2
)in -
sulated engine. So, the use of the (Al
2
O
3
-TiO
2
) insulation
together with blend POME is suitable for the given en-
gine.
5.2 Engine exhaust emissions
5.2.1 Brake power versus carbon monoxide emissions
The variation in the brake power versus carbon mon-
oxide (CO) emissions is shown in Figure 8. The objec-
tive of comparing (POME) B25, B50, B75, B100 and
conventional diesel, and the (Al
2
O
3
-TiO
2
) coated engine
leads to reduced carbon monoxide emissions. The results
reveal that the conventional engine causes a high level of
emissions due to an inadequate level of the oxygen
content when tested in the POME (Al
2
O
3
-TiO
2
) coated
engine, while the carbon monoxide emissions decrease
considerably.
5.2.2 Brake power vs hydrocarbon emissions
Hydrocarbon emissions are reduced substantially
when the right blend of POME and oxygen (air-fuel mix-
ture) is released into the combustion chamber. When the
conventional diesel and oxygen are let into the combus-
tion chamber, hydrocarbon emissions are very high since
the conventional diesel and oxygen do not mix easily.
The intention is to find out which of the three variables
(various blends of POME including B25, B50, B75,
B100 or the conventional diesel or the (Al
2
O
3
-TiO
2
)
coated engine) results in lower hydrocarbon-emission
levels. Figure 9 reveals that POME together with the
(Al
2
O
3
-TiO
2
) coated engine results in a lower amount of
hydrocarbon emissions, whereas the conventional engine
releases large amounts of hydrocarbon emissions.
5.2.3 Brake power vs NOx emissions
The variation in the brake power versus NOx engine
emissions is shown in Figure 10. The conventional die-
sel leads to high NOx-emission levels and when the con-
ventional diesel is released into the combustion chamber,
the temperature soars and produces NOx emissions. To
surmount the problem of unacceptably high levels of
NOx emission, the (Al
2
O
3
-TiO
2
) coated engine is in-
serted into the modified TV1 Kirlosker diesel engine. It
is revealed that the coated engine is able to absorb a cer-
K. MURUGAN, R. THIRUMALAI: EXPERIMENTAL ANALYSIS OF THE THERMAL-BARRIER COATING ...
Materiali in tehnologije / Materials and technology 55 (2021) 1, 121–126 125
Figure 8: Brake power versus CO emission
Figure 6: Brake power versus brake specific fuel consumption
Figure 9: Brake power versus hydrocarbon emissions
Figure 7: Brake power versus air-fuel ratio
Figure 10: Brake power versus NOx emissions

tain level of heat. Hence, the temperature comes down
and results in lower NOx emissions. The objective is to
find out which of the two variables including the conven-
tional diesel and (Al
2
O
3
-TiO
2
) coated engine leads to
lower levels of NOx emissions. The blend (POME) and
coated engine lead to lower emissions, whereas the con-
ventional diesel leads to higher NOx emissions.
5.2.4 Brake power versus smoke opacity
Figure 11 predicts the variation in the brake power
versus the smoke opacity. The conventional-diesel en-
gine demonstrated higher smoke opacity, which can be
ascribed to the high amount of the fuel content in the
conventional engine. The result revealed that POME and
the (Al
2
O
3
-TiO
2
) ceramic powder insulating the engine
lead to lower smoke opacity. On the other hand, the con-
ventional-diesel engine demonstrated higher smoke
opacity. This can be ascribed to the high amount of fuel
content in the conventional engine.
6 CONCLUSION
The coated-engine temperature leads to a work ex-
pansion by increasing the brake thermal efficiency for
the suitable engine at the maximum load. The
(Al
2
O
3
-TiO
2
) coated, blend (POME) engine enhances
combustion, reduces heat energy and decreases the brake
specific fuel consumption. The results emphasize the ef-
ficiency of the POME (Al
2
O
3
-TiO
2
) coated engine with a
modified piston using the 75 % blend and exposed to a
full load. The results also reveal that the CO-emission
level and NOx emissions are significantly reduced when
the blend (POME) (Al
2
O
3
-TiO
2
) coated engine is used. In
addition, the HC emissions are gradually increased. The
study also highlights the fact that the smoke opacity
came down as compared with the conventional-diesel en-
gine. Thus, the Al
2
O
3
-TiO
2
coated engine using blend
POME can reduce the discrepancy between economic
development and preservation of human health.
Acknowledgement
The authors wish to thank Aum Surface Technology
Bangalore for the coating services.
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Figure 11: Brake power versus smoke opacity