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Adiabatics, Inc. with the support of the U.S. Army Tank Automotive & Armaments Command has examined the feasibility of using Diamond Like Carbon (DLC) films and Iron Titanate (Fe2TiO5 or IT) for sliding contact surfaces in Low Heat Rejection (LHR) diesel engines. DLCs have long been a popular candidate for use in sliding contact tribo-surfaces where a perceived reduction of friction losses will result in increased engine efficiency [1]. There exists a broad range of technologies for applying DLC films. This paper examines several types of these technologies and their future application to automotive internal combustion engines. Our work focuses upon DLC use for LHR military diesel engines where operating temperatures and pressures are higher than conventional diesel engines. However, a direct transfer of this technology to automotive diesel or gasoline engines exists for these thin films.

A high output experimental single cylinder diesel engine that was fully coated and insulated with a ceramic slurry coated combustion chamber was tested at full load and full speed. The cylinder liner and cylinder head mere constructed of 410 Series stainless steel and the top half of the articulated piston and the cylinder head top deck plate were made of titanium. The cylinder liner, head plate and the piston crown were coated with ceramic slurry coating. An adiabaticity of 35 percent was predicted for the insulated engine. The top ring reversal area on the cylinder liner was oil cooled. In spite of the high boost pressure ratio of 4:1, the pressure charged air was not aftercooled. No deterioration in engine volumetric efficiency was noted. At full load (260 psi BMEP) and 2600 rpm, the coolant heat rejection rate of 12 btu/hp.min. was achieved. The original engine build had coolant heat rejection of 18.3 btu/hp-min and exhaust energy heat rejection of 42.3 btu/hp-min at full load.

This paper investigates theoretically the effects of heat transfer characteristics, such as crank-angle phasing and wall temperature swings, on the thermodynamic efficiency of an IC engine. The objective is to illustrate the fundamental physical basis of applying thin thermal barrier coatings to improve the performance of military and commercial IC engines. A simple model illustrates how the thermal impedance and thickness of coatings can be manipulated to control heat transfer and limit the high temperatures in engine components. A friction model is also included to estimate the overall improvement in engine efficiency by the proper selection of coating thickness and material.

The contemporary turbocharged aftercooled diesel engine is providing the world with one of the most efficient and dependable powerplants known to mankind. An adiabatic turbocompound diesel engine is analyzed in this paper to demonstrate that the contemporary diesel cycle without a cooling system could be the beginning of a new era in continued diesel engine efficiency, reliability and durability. The problems with the diesel cooling system encountered in service are presented. The consequence of an adiabatic turbocompound engine without any cooling system is treated for engine performance.

Cummins Engine Company, Inc. and the U.S. Army have been jointly developing an adiabatic turbocompound engine during the last nine years. Although progress in the early years was slow, recent developments in the field of advanced ceramics have made it possible to make steady progress. It is now possible to reconsider the temperature limitation imposed on current heat engines and its subsequent influence on higher engine efficiency when using an exhaust energy utilization system. This paper presents an adiabatic turbocompound diesel engine concept in which high performance ceramics are used in its design. The adiabatic turbocompound engine will enable higher operating temperatures, reduced heat loss, and higher exhaust energy recovery, resulting in higher thermal engine efficiency. This paper indicates that the careful selection of ceramics in engine design is essential.