Beruflich Dokumente
Kultur Dokumente
By Yasuo Miyagi * *
1. Introduction
Apart from the above, seven shipbuilding compa-
The utilization of fine ceramics for heat engines as nies jointly established "Technical Research
structural material, high temperature material in Association for Reliable Marine Propulsion Plants" with
particular, has been actively studied since 1970's. the purpose of "Research and development of highly
Researches on the application of fine ceramics to high reliable marine propulsion plants" in September of 1983
temperature components of gas turbine engines such as under the leadership of the Ministry of Transport. This
nozzle and turbine blades started mainly in western association had conducted tasks until March of 1989
countries. under the sponsorship of Japan Shipbuilding Industry
Being coincident with the oil crisis at that time, Foundaiton. Among these tasks, this association studied
researches on the application of fine ceramics to diesel improvements in engine performance and reliability that
engines, automobile and vehicle engines in pal1icular, enabled engines to be operated without maintenance for
also started feverishly. a long period of time by utilizing ceramics for
The council for Transport Technology submitted its improving the heat resisting and sliding properties of
report titled "The development of shipbuilding combustion chamber components .
tech-no1ogy to be promoted in the future in response to Following the completion of projects of the said
recent change in industrial structure and progress in technical research association, the joint-stock company
elemental technology" (Report on Inquiry No.13) in ADD that was financed by the subsidy of Association
August of 1982, in which the following two subjects for Structural Improvement of the Shipbuilding Industry
were also taken up. One is "High1y reliable plants" and the joint investment of Mitsui Engineering &
related to "Technologies to realize intelligent and highly Shipbuilding Co., Ltd., Kawasaki Heavy Industries Ltd.,
reliable Ships" and the other is "Fundamental researches Hitachi Zosen Corporation and Japan
on engines using alternative fuels such as super low Development Bank was established in September of
grade fuel oil, coal, and hydrogen" related to "Subjects 1989 in order to inherit and evo1ve the fruits of research
to cope with the 21st century". Researches on the by the said technical research association. ADD is
application of fine ceramics to marine diesel engines positively forwarding researches on "Test and research
started in earnest in response to the statement in the of highly reliable marine propulsion plants" including
aforementioned report saying that "It is expected to fields where ceramics are utilized, still now.
positively utilize ceramics, electronics and space Ship Research Institute of the Ministry of Transport
technology". also started researches on the utilization of ceramics for
In response to the aforementioned report, the marine heat engines in 1966. In an early stage, ceramics
Maritime Technology and Safety Bureau (the then Ship based on oxides such as alumina and mullite were taken
Bureau) of the Ministry of Transport established into consideration with the purpose of the uti1ization of
"Specialists' Conference for Investigation and Research them for special heat exchangers for marine gas turbines.
on Adiabatic Diesel Engines". Following to this, Japan When started research, everything had to be done by
Marine Machinery Development Association feel without having any strength test data, and the
established "Task Committee for Investigation and corrosion resistance of ceramics against ash in heavy
Research on Adiabatic Diesel Engines" and had fuel oil had been studied by various high temperature
conducted tasks until March of 1987. strength and high temperature fatigue test methods by a
―――――――――――――――――――――― trial and error approachl).
* Translated from Journal of MESJ Vo1.28, No.9 Ship Research Institute started the researches on
(Manuscript received Jun. 15, 1993 ) the utilization of ceramics for diesel engines in earnest
Lectured May 27, 1 993 since the research on consignment "Research and
development of ceramic components of diesel engines"
** Ship Research Institute (6-38-1, Shinkawa in 1982, which accelerated researches on ceramics. It
,Mitaka, Tokyo, JAPAN)
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70 Yasuo Miyagi
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72 Yasuo Miyagi
shows smoke density of a level of 20% at full load and examination experimentally by the methods of applying
rated speed. However, the smoke density of every type reagents to test pieces and exposing test pieces in the
of engine lowers down to the range from 1/5 to 1/4 at combustion gas flow.
ful1 1oad and rated speed when using emulsified fuels
with 30% water. At 3/4 load, smoke density is zero 4.2.1 Tests by Reagent Applying Method4)
percent in the whole range of operating speed. Though A part of results of corrosion resistance tests
the smoke density of the ceramic engine with reduced applying reagents to test pieces which were conducted
cooling loss tends to increase at an injection timing of in the electric furnace were already lectured at the
24 , it is still zero percent at 3/4 1oad. lecture meeting of this society5). Though the corrosion
resistance of ceramics is considered excellent in general,
4.1.3 Heat Release Rate and Specific Fuel some materials may cause prob1ems on corrosion
Consumption resitance against low grade heavy fuel oil which is main
Fig. 7 shows the heat release rate of every type of fuel for marine engines, since this fuel oil includes
engine under conditions of an injection timing of 30 vanadium and sodium of about 100ppm each.
,1800rpm and full load, and Fig. 8 shows the same of
the ceramic engine with reduced cooling loss when its 4.2.1.1 Test Procedures
injection timing was changed. The ignition of the Five kinds and six products of ceramics which are
ceramic engine with reduced cooling loss becomes popular as structural material were used for this test.
earlier by about l.5 degrees in comparison with that of Table 3 1ists these ceramics. The shapes of test pices are
the metallic engine as a matter of couse. in accordance with JIS R 1601 "Testing Method for
When the injection timing is retarded, combustion Flexural Strength (Modulus of Rupture) of High
in an ear1y stage lessens, the range of diffusion Performance Ceramics". Namely, they are rectangular
combustion widens and the peak of the heat release rate pieces of 4mm in width, 3mm in height and 40 to 45
approaches TDC. mm in length.
Fig. 9 also shows specific fuel consumption in Table 4 shows experimental conditions in
response to the above. Specific fuel consumption accordance with GAKUSHIN-HO6) (the method
figures were corrected using correction factors in JIS D established by Japan Society for the Promotion of
l005-1986. The ceramic engine with reduced cooling Science). The reagent was a mixture of V2O5 and
loss has specific fuel consumption which is comparable Na2SO4 in the ratio of 85% to 15% into which acetone
to that of the metallic engine using gas oil as fuel, and it was added, and it was applied to the upper surfaces of
is considered that the injection timing of the former can test pieces at the rate of 2Omg/cm2 on the average.
be retarded further under the conditions of low speed Tests were conducted in the temperature range
and low 1oad. from 500 C to 1400 C, using a temperature of 800
C specified by GAKUSHIN-HO as a standard and
4.2 Corrosion Resistance of Ceramics taking
The corrosion resistance of ceramics against ash
and molten salts in heavy fuel oil is now under
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ers indenter by 30 kgf were also tested. checking its strength, so far. When using this method,
Fig. 14 shows results of tests under the conditions plenty of time and labor are needed since many test
of an exposure time of 49 hours (7 hours 7 times) and pieces must be tested, and, furthermore, values obtained
exposure in the furnace. Though the influence of the are sometimes unsuitable for comparison since heat
application of sodium sulfate is extremely great on test transferring conditions around test pieces vary
pieces without cracks, it is far small on those with depending on the conditions when dropping test pieces
cracks (marks with bars in the figure). The rupture down. This method can also be said to be unsuitable
strength of test pieces with cracks and without sodium when unhomogeneous material with leaning function is
sulfate lowers down to one third. Test pieces tested in measured .
the gas flow have almost equal strength of those tested In the method mentioned here, material surfaces
in the furnace in case of the gas with additives and are irradiated with laser beams and the thermal shock
strength lowers when kerosene with a small amount of resistance of materials is evaluated by output density
impurities is used. Judging from these results, it is and spot diameters at the time of rupture. This method
considered that the toughness of materials with surface was proposed and research for it was started recently. In
cracks is improved with molten salts and their this method, the thermal shock resistance of a test piece
sensitivity to notches gets dul1. It is therefore can be evaluated by measuring a power value at the
considered unnecessary to worry about surface finish moment when it cracks with a n'1onitor such as AE
when using ceramics in a corrosion atmosphere. while changing laser power. Ship Research Institute is
now forwarding work for theoretically substantiating
4.3 Friction and Wear Tests this method by performing model calculation through a
Though tests and researches on the friction and finite element method and comparing its results with
wear properties of ceramics in the vincinity of ordinary measured values9).
temperature have been conducted at various places, test
data under high temperature are almost unavailable. The 4.5 Nondestructive Inspection Using Laser
friction and wear properties of ceramics are important in Ultrasonic Wave
cases where ceramics are applied to components having The laser ultrasonic wave method is considered
high temperature sliding surfaces such as piston rings, promising as a method of the nondestructive inspection
cylinder sleeves and exhaust valves of diesel engines. of ceramics. This method can generate and detect
As shown in Fig. 15, the test equipment can raise ultra-sonic waves without contact and can substantially
its temperature up to 1000 C by external high increase the speed and improve the performance of
frequency induction heating. Tests by the ring-on-disk inspection. It can also evaluate materials and defects of
method or pin-on-disk method can be conducted in the machinery and equipment in service. Thanks to these
range of pressing load from one to 50 kgf and of rotating properties, it becomes possible to investigate the
speed from 5 to 500rpm. propagation characteristics of laser ultrasonic waves and
Fig. 16 shows results of tests conducted on alumina the behavior of their echoes, to devise the method of
and mullite of oxide ceramics8). Their specific wear treating the wave forms of detected data, and to obtain
losses decrease by more than one figure under high linear responses10). Thus, it is considered that this
temperature. It was found that the surface layer method can be utilized as more quantitative ultrasonic
consisting of fine particles as shown with a model in wave measurement technique.
Fig.17 was formed on the surface which was rubbed
under high temperature. Judging from this fact, the 4.6 Reseraches on the Mechanism of Ceramic
following can be concluded. Namely, in the case where Sp raying
the temperature of the part near the surface which For spray coating, the spray conditions of plasma
receives shear deformation is sufficiently high, the guns and the strength of sprayed material have been
surface layer consisting of fine particles is formed empirically clarified so far, but its intermediate process
through plastic deformation entailing recrystallization is not clarified yet. Ship Research Institute is now
and specific wear loss decreases thanks to the con-ducting fundamental researches to clarify processes
considerably high plasticity of the fine particle layer such as the formation of plasma flow by arc discharge,
under high temperature plasma heat transfer to ceramic particles, rapid cooling
. and deformation on the base material and film formation
4.4 Evaluation of Thermal Shock by Laser by building up so1idified particles, and to develop
The evaluation of thermal shock resistance has excellent ceramic coating techniquesl1). It is also
generally been expressed by temperature difference that con-ducting researches on an improvement in wear
causes strength reduction by dropping a high tempera- resistance by improving the quality of ceramic coating
ture test piece into water or oil for rapid cooling and by
5. Conclusion
The test engine had been operated on water
Though ceramics inherently have many properties emu1-sified fuels for more than 200 hours in total.
such as heat resistance, corrosion resistance and wear During this period of time, its combustion chamber
resistance better than those of metal, products which are components were observed at intervals of about 30
put to practical use as engine components are still few. hours. We could not detect any particular change in the
Since fine ceramics were developed as structural material quality of these components including ceramic
material only about a quarter of a century ago, it is components.
natural that they have many points which have not been
clarified yet. Research and development have often been References
conducted so far on ceramics having a single component
such as alumina, silicon nitride and silicon carbide in the 1) Miyagi, Y., Fujimoto, Y., Journal of M.E.S.J., vo1.
main. It is considered that the function and performance 16,No. 8,P. 30-38,(1981)
of ceramics will be improved through the composition 2) Nishikawa, K., Miyagi, Y., Shiode, K., Journal of
of components like metallic al1oys and that ceramics MESJ, vo1. 26, No. 9, P. 128-132, (1991 )
with properties suited to uses will appear in the future. It 3) Nishikawa, K., Miyagi, Y., Shiode, K., Preprint of
is also thought that more ceramics will be practically 57th general meeting of Ship Research Institute,
used at proper positions by combining well with p.135-138, (May, 1991)
metallic materials in the future, since it has become 4) Miyagi, Y., Fujimoto, Y., Preprint of 49th genera1
possible to substantially reduce molding and machining meeting of Ship Research Institute, p.
costs by the near-net-shape method. The author 148-151,(June, 1987)
expects that high-performance and low-cost engines 5) Miyagi, Y., Fujimoto, Y., Preprint of 39th lecture
requiring almost no maintenance work will be realized meeting of MESJ, p. 37-40, (Oct., 1986)
with the aid of ceramics in the 2 1st century. 6) The 123rd Committee for Heat resisting Metal of
Discussion Japan Society for the Promotion of Science, "The
Masanori Tanaka (Mitsui Engineering & method of corrosion test at high temperature by
Ship-building Co., Ltd.) spreading V2O5-Na2SO4 synthetic ash", ( 1973)
How many hours did you operate the test engine 7) Munakata, Y., Senda T., Preprint of 70th Annua1
using water emulsified fuels? Do you obtain any Meeting of JSME, Vo1. B4-6, (Sep., 1992)
information on the durability of combustion chamber 8) Senda T., Preprint of 59th general meeting of Ship
components during operation? Research Institute, p. 73 -76, (May, 1992)
9) Akiyama, S., etal, Preprint of 70th Annula Meeting
of JSME, Vo1. B 13-6, (Sep., 1992)
10) Shimada, M., Yoshii, T., Preprint of 6 1 st genera1
meeting of Ship Research Institute, p. 34-37,
(June,1993)
11) Takahashi, C., Senda, T., Preprint (/)f 59th genera1
meeting of Ship Research Institute, p. 69-72,
(May,1992)
October1994 (9)