Effect of Metallic and Ceramic Coatings on Structural Behavior of Heavy‐Duty V8 Engine Using Finite Element Analysis

Abstract

This research aims to compare the effects of material coatings on the structural behavior of a V8 engine block to identify the most suitable coating material that can enhance structural integrity and functionality under different pressures. SolidWorks 20.0 is used for designing V8 engine block, and ANSYS Workbench 19.0 for coating simulations. Six coating materials are selected including Zirconia (ZrO2), Alumina (Al2O5), Tungsten Carbide (WC), Nickel (Ni), Silicon Nitride (Si3N4) and Silicon Carbide (SiC). These coatings are applied to the interior surface of the engine cylinders, with a thickness of 0.4 mm. The performance of each coating material is analyzed under three different pressure conditions, 6.90, 8.27, and 9.65 MPa. The results yielded that Tungsten Carbide is the optimal material for coating a V8 engine when used with the base material of Aluminium, as it displayed the lowest values of deformation, stress, and strain. As a result, the structural behavior is improved by 30% as compared to the base material. Moreover, the factor of safety exhibit a significant increase. Based on the results, the Tungsten Carbide coating can significantly reduce stress levels and increase the safety factor, thereby potentially improving the durability and performance of the V8 engine block.