Evaluation of improved materials for stationary diesel engines operating on residual and coal-based fuels. Final report

An investigation of materials which must function in present and future diesel engines is described. The quality of the petroleum based fuels available for stationary engines is steadily declining, and the engine ratings are steadily increasing. If the modern, highly efficient diesel engine is to retain its place in the power generating field, advances in the tribology of engine components are required. This is even more important if these engines are to burn successfully residual fuels and the coal-based liquid fuels and coal-oil slurries which will replace the more refined petroleum based fuels. This progam evaluates ceramic coatings and monolithic ceramics which could be incorporated into the design of stationary piston engines to allow: the use of fuels which are considerably below current standards as regard to corrosive and abrasive contaminants. These fuels include low grade residual oils from petroleum stocks, coal-based liquid fuels, and coal-oil slurries, as outlined in the Alternative Fueled Stationary Diesel National Program, Division of Power System, the Department of Energy, April 1978; operation at higher mean effective pressure to increase the efficiency and reduce the size of the engine; and a reduction in wear of critical components to thereby increase the engine's service life. Recognizingmore » the complexity of a subject such as friction and wear in a reciprocating engine with the many possible interactions of wear mechanisms, materials, lubricants, surface condition and finish, operating conditions, etc, the program includes the identification and characterization of potential materials which might be incorporated into existing engine designs; screening of these materials with relatively simple laboratory apparatus especially designed for this purpose; SEM analysis of the wear surfaces; and the development of an accelerated wear test utilizing a single-cylinder diesel engine burning a coal-oil mixture.« less