Experimental and computational investigation of FGM coated cylinder liners prepared using HVOF technique

Abstract In the present work, to improve the wear resistance of the cylinder liner, without affecting the heat dissipation, cast steel cylinder liners are coated with five-layer Functionally Graded Material (FGM) coatings prepared using High-velocity oxy-fuel (HVOF) technique. The powders were designated as C 1 (WC-10Co-4Cr) which is Tungsten Carbide with 10% Cobalt and 4% Chromium, C 2 (WC-12Co) which is Tungsten Carbide with 12% Cobalt and C 3 (Ni-25Cr) which is Nickel with 25% Chromium. The results revealed that the FGM coating designated as Functionally Graded Coated Sample-1 (FGCS-1) wears less compared to Functionally Graded Coated Sample-2 (FGCS-2) and Functionally Graded Coated Sample-3 (FGCS-3), due to the presence of wear resistive elements in the composition and uniform material homogeneity. Numerical analysis of FGCS-2, conducted using Ansys Fluent software, revealed a negligible temperature gradient across the coating thickness. This is due to the highly conductive coating material and the extremely thin coating layers, making it suitable for engine cylinder liner applications where less wear and high heat transfer rate is desirable.