IIT MADRAS PAPER PRESENTATION in thermal topics

analysis

1. THERMAL MANAGEMENT SOLUTIONS S.NO TEAM MEMBERS YEAR 1. BHAVANKUMAR P III 2. ARUN KAILASH K III 3. MAHARAJAN SG III 4. K HARIPRASATH III

2. PROBLEM STATEMENT In high-temperature applications, effective thermal management is crucial. The challenge lies in developing thermal barrier coatings that can reduce the outer surface temperature by 400 to 500 degrees Celsius . These coatings must withstand extreme heat while providing insulation to the underlying components, preventing heat transfer and structural damage. Achieving such coatings requires advanced materials engineering, precise deposition techniques, and thorough testing to ensure durability and performance under harsh conditions.

3. PROPOSED IDEA/SOLUTION 1. Given that Thermal Barrier Coatings like Yttria Stabilized Zirconia can reduce heat by up to 150-200 degrees Celsius. 2. We have introduced a novel design. This design features a lattice structure within the exhaust manifold filled with zirconia , augmented with a small amount of graphene, to capture and release heat slowly to the outer surface. 3. This design is capable of reducing 400-500 deg Celsius in accordance with problem statement. 4. Furthermore, we employ advanced techniques such as metal additive manufacturing for product fabrication.

4. MATERIAL SELECTION 1.Inconel 625/SS330: Inconel 625 (K=20w/m-k)is a nickel-based superalloy known for excellent corrosion resistance and superior strength at elevated temperature[1]. SS330 is also suggested (research articles is not found). 2.Zirconia mixed with graphene powder: Zirconia (k=5w/m-k) is known for its lower thermal conductivity, which slows down heat dissipation and also gives better mechanical performance[2]. 3.Yttria Stabilized Zirconia(YSZ): As of now YSZ (k=0.9 w/m-k) is noted for enhanced performance compared to other process used for the thermal barrier coating (TBC)[3].

5. PRODUCTION LINE DESIGN SLM PROCESS (ZrO 2 , GRAPHENE) WITH METHYL ACETATE EVAPORATION PIEZO-ELECTRIC ACTUATOR F INISHED PRODUCT THERMAL BARRIERCOATING (HVAF)

6. SAMPLE DESIGN Inner wall Lattice structure Outer wall Fig1: Sample design of exhaust pipeline

7. RESULTS Fig 2: Simulation Of Exhaust Manifold

8. Temperature( deg C) vs Arc length(mm) graph YSZ INCONEL 625 LATTICE WITH ZIRCONIA INCONEL 625 YSZ

9. Zirconia and graphene heat dissipation with strut Heat dissipation STRUT(INCONEL LATTICE) ZIRCONIA WITH GRAPHENE ZIRCONIA WITH GRAPHENE Weight percentage of zirconia -85% Weight percentage of lattice structure-15%

10. REFERENCES [1]. Benchmark Study of Thermal Behavior, Surface Topography, and Dendritic Microstructure in Selective Laser Melting of Inconel 625 Zhengtao Gan, Yanping Lian, Stephen E. Lin, Kevontrez K. Jones, Wing Kam Liu & Gregory J. Wagner. [2]. Superior Thermal Conductivity of Single-Layer Graphene Alexander A. Balandin, Suchismita Ghosh, Wenzhong Bao, Irene Calizo , Desalegne Teweldebrhan , Feng Miao, and Chun Ning Lau. [3]. Morphology and thermal conductivity of yttria-stabilized zirconia coatings ( Hengbei Zhao). [4]. Selective Laser Melting Of Curved Surface Metal Parts: A Fundamental Study On Surface Finish And Dimensional Accuracy Shrouq Alelaumi , Ali Khoshkhoo , Fuda Ning. [5]. Thermal Conductivity Analysis and Lifetime Testing of Suspension Plasma-Sprayed Thermal Barrier Coatings Nicholas Curry , Kent VanEvery, Todd Snyder and Nicolaie Markocsan . [6]. Thermal Barrier Coatings for Heavy-Duty Diesel Engines ANDERS THIBBLIN . [7]. Modelling Thermal Conductivity of Porous Thermal Barrier Coatings Ramandeep Singh Ghai 1, Kuiying Chen 2,* and Natalie Baddour . [8]. Thermal Fatigue Analysis of Exhaust Manifold Ms. Neha N. Shinde, Mr. A. A. Panchwadkar .

11. THANK YOU

12. VALUES INCONEL 625 = 1292 – 1350 deg C (melting point) Operating temperature = 1000 deg C Operating temperature of YSZ = 1600 deg C

13. 1.SELECTIVE LASER MELTING: Selective Laser Melting (SLM) is an powder bed fusion process which is suitable to fabricate intricate and complex shapes. We have chosen this to fabricate the lattice structure.[4] TECHNOLOGY USED 2. High Velocity Air Fuel Technique : On comparing to other coating processes, HVAF is recorded for low thermal conductivity for as-produced YSZ and also withstand high thermal cycles [5]. For low cost fabrication, APS is suggested[6]. 3.PIEZO-ELECTRIC ACTUATOR: Actuator is used for fine mixing and distribution of the zirconia and graphene. 4. CUSTOMIZED FURNACE SETUP: In order to maintain mixing and evaporation alternatively customized furnace would be used to hold actuator.