Modern engines, whether internal combustion engines (ICE) or gas turbine units (GTD), operate under conditions of high temperatures and significant mechanical loads. The durability, efficiency and reliability of these units directly depend on what materials are used in their design. Let's consider the main types of alloys and steels used in internal combustion engines and gas turbines, and find out why it is important to choose the right option.
Materials for internal combustion engines
An internal combustion engine is a type of heat engine in which the chemical energy of fuel is converted into mechanical work.
The main components of the engine include:
- Cylinders — hollow metal elements that provide a working space for igniting fuel. They are usually made from durable metals that are resistant to wear and tear.
- Pistons — movable elements that move in cylinders and transfer the force from fuel combustion to the crankshaft, ensuring its rotation.
- Crankshaft — a rotating part that converts the reciprocating movement of the pistons into torque.
- Connecting rods — connect the pistons to the crankshaft.
- Valves — regulate the supply of the air-fuel mixture to the cylinders (inlet valves) and the exhaust gas outlet (exhaust valves).
- Ignition system — initiates fuel ignition due to a spark that occurs when an electrical impulse is applied to the spark plugs.
- Lubrication and cooling systems — protect the unit from overheating and wear and tear, prevent mechanical damage when moving elements of the engine are operating.
The engine is based on the principle of burning a mixture of fuel and air in the cylinder, which causes the expansion of gases and leads to the movement of the piston. A fuel-air mixture is supplied to the combustion chamber, which is compressed by the piston to the upper dead center and ignited by the spark plug. As a result of ignition, the gases expand, which in turn causes the piston to move down to the lower dead center. When this point is reached, the piston energy is transferred through the connecting rod to the crankshaft, driving it. At the same time, the exhaust gases leave the cylinder chamber through the exhaust valve, and the cycle is repeated. In order for this process to take place efficiently and reliably, special alloys are used in the engine.
The main materials used in the internal combustion engine:
- Cast iron. It is often used for the manufacture of cylinder blocks and block heads. The material is known for its high strength and resistance to wear, which is especially important for parts exposed to high temperatures and pressures.
- Aluminum and its alloys. Pistons, connecting rods and valves are often made of aluminum alloys. Aluminum is valued for its low weight and sufficient strength, which reduces engine weight and improves its dynamic characteristics, while maintaining the reliability and durability of the structure.
- Copper alloys. Due to their high thermal conductivity, copper and its alloys are ideal for cooling systems, in particular for radiators and pipelines. Copper is also resistant to corrosion, which extends the life of such elements.
- steel. Steel alloys are used for key mechanical units such as crankshafts and camshafts. Steel is characterized by increased strength and hardness, which ensures high wear resistance of components operating under constant loads.
The use of each of these materials helps maintain optimal engine performance under conditions of high temperatures, heavy loads and wear during operation. For example, improving thermal conductivity or reducing the weight of individual components can reduce fuel consumption and improve overall engine performance.
Materials for gas turbine engines
Gas turbines are widely used in aviation, energy and other industries where high power and reliability are important. The principle of operation of these engines is based on converting the energy generated during the combustion of fuel into mechanical operation or kinetic energy of the jet (reactive thrust). One of the key points is the ability of materials to withstand extreme temperatures and loadsthat the parts of the unit collide with.
The main parts of the GTD include:
- Compressor — provides air compression before it is supplied to the combustion chamber.
- Combustion chamber — a place where the fuel mixture is burned and hot gases are formed.
- Turbine — converts gas energy into mechanical work.
- Nozzle — removes gases from the engine, creating jet propulsion.
The operating principle of a gas turbine unit is based on the continuous combustion of fuel at constant pressure. The air entering the compressor is compressed and sent to the combustion chamber. Fuel is also supplied there, which mixes with air and burns to form hot gases. These gases expand and rotate the turbine, which is connected to the compressor and nozzle. The nozzle sends gases into the environment, creating a reactive force that drives the turbine.
The main materials used in gas turbine engines:
- Heat-resistant steels and nickel-based alloys. These materials are used to manufacture parts that operate at extreme temperatures, such as turbine blades and combustion chambers. Nickel alloys They have high heat resistance, corrosion resistance and fatigue resistance, which allows them to maintain their properties even at temperatures exceeding 800°C.
- Titanium alloys. They are widely used for the manufacture of parts where lightness and high strength are important, for example, for turbine discs. These alloys are characterized by low density and corrosion resistance, which is especially important when working in corrosive environments.
The choice of materials for gas turbine engines is due to the need to withstand high thermal and mechanical loads. Therefore, nickel and titanium-based alloys are becoming indispensable in the design of modern gas turbines.
Special steels and alloys produced by PZPS: resistance to corrosion and high temperatures
For both engine categories, it is essential to use corrosion-resistant, heat-resistant and heat-resistant materials. IN modern mechanical engineering have proven themselves well:
- Corrosion-resistant steels and alloys (10X17N13M3T, 12X18N9, 12X18H10T, 12X18N9SMR and others) — prevent corrosion damage that can lead to premature wear of parts. Their use extends the life of engines and reduces repair and maintenance costs.
- Heat-resistant steels and alloys — used for the manufacture of components operating at temperatures up to 1250°C, such as combustion chambers and exhaust valves. Heat resistance allows materials to maintain their properties even under prolonged exposure to extreme temperatures.
- Heat-resistant steels and alloys, such as 20X13 et HN78T — used for parts operating at high temperatures and mechanical loads (for example, turbine blades and compressor discs). Inconel alloys (625, 718 and S-276), whose analogues are produced at PZPS, are among the best in terms of heat resistance and are widely used in the aviation and power industries.
The use of high-quality steels and alloys in internal combustion engines and gas turbine units can significantly increase their service life, reduce the frequency of maintenance and increase the overall reliability of equipment. The introduction of such materials also contributes to improving fuel efficiency, which is especially important for modern vehicles and power plants.
Partnership with the St. Petersburg Precision Alloy Plant
PZPS offers wide range high-quality heat-resistant, corrosion-resistant and heat-resistant steels and alloys for internal combustion engines and gas turbines. We guarantee high standards of product quality and reliability that meet international requirements.
PZPS alloys have:
- resistance to high temperatures;
- increased strength under intense mechanical loads;
- corrosion resistance in aggressive environments;
- lightness and high specific strength.
For more information on available materials and to order products contact us. Our experts will help you find the best solutions for your production!
