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The effects of aluminum, ductile iron, and superalloy piston materials; air gaps; and plasma-sprayed zirconia coating on piston temperature and stress, as well as on heat flux through the piston, are assessed. ...The effects of aluminum, ductile iron, and superalloy piston materials; air gaps; and plasma-sprayed zirconia coating on piston temperature and stress, as well as on heat flux through the piston, are assessed. The coating lowered the heat flux through the piston 56 percent and caused other changes in the piston to have an insignificant effect on the heat flux.

The HVOF coating is considered to be an excellent replacement for chrome plating. The coating process is more environmentally friendly than the chrome plating process. ...High Velocity Oxygen Fuel sprayed face coatings have shown great promise for piston rings used for High Power Density Diesel Engines. Various coatings have been tested on both wear test rigs and in engines. ...Various coatings have been tested on both wear test rigs and in engines. A highly dense HVOF cermet coating was developed with reasonable crack resistance during service.

A number of wear resistant coatings has been developed using physical vapor deposition(PVD) process. However this coating process has not yet been widely used in the automotive industry. ...The purpose of this work was to evaluate thin PVD coatings such as diamond like carbon doped with tungsten (W-DLC), molybdenum-disulfide doped with aluminum (MoS2-Al), and chrome nitride (CrN). ...Some of these coatings were previously found to have low friction, high wear resistance, or both when tested in unlubricated conditions.

Scuff resistance of electrolytic chrome, thermal spray and physical vapor deposition (PVD) face coatings have been examined. Based on this method, examined PVD coatings produced the highest scuff resistance of all the tested face coatings. ...A laboratory method has been developed to rank the scuff resistance of piston ring coatings. This method employs a standard wear test apparatus with a specially designed sample holder. ...Based on this method, examined PVD coatings produced the highest scuff resistance of all the tested face coatings.