formula 1 racing: silicon nitride engine levi lentz greg berkeley christian igartua javies banuelos...
TRANSCRIPT
![Page 1: FORMULA 1 RACING: SILICON NITRIDE ENGINE Levi Lentz Greg Berkeley Christian Igartua Javies Banuelos Arthur Kluch](https://reader030.vdocument.in/reader030/viewer/2022033103/56649ebd5503460f94bc6e24/html5/thumbnails/1.jpg)
FORMULA 1 RACING: SILICON NITRIDE ENGINE
Levi LentzGreg Berkeley
Christian IgartuaJavies Banuelos
Arthur Kluch
![Page 2: FORMULA 1 RACING: SILICON NITRIDE ENGINE Levi Lentz Greg Berkeley Christian Igartua Javies Banuelos Arthur Kluch](https://reader030.vdocument.in/reader030/viewer/2022033103/56649ebd5503460f94bc6e24/html5/thumbnails/2.jpg)
Why a Formula 1 Racing Engine?
- Can an internal combustion engine be more efficient by changing the materials used?
- Can an internal combustion engine create more power with the same amount of fuel?
![Page 3: FORMULA 1 RACING: SILICON NITRIDE ENGINE Levi Lentz Greg Berkeley Christian Igartua Javies Banuelos Arthur Kluch](https://reader030.vdocument.in/reader030/viewer/2022033103/56649ebd5503460f94bc6e24/html5/thumbnails/3.jpg)
OUR COMPETITIONThe spending per team is as follows:• McLaren Mercedes: $400M• Toyota: $393M• Honda : $382M• BMW Sauber: $378M• Ferrari: $329M• Renault: $300M• Red Bull Racing: $201M• Williams: $134M• Super Aguri: $95M• Midland F1: $76M• Scuderia Toro Rosso: $66M
![Page 4: FORMULA 1 RACING: SILICON NITRIDE ENGINE Levi Lentz Greg Berkeley Christian Igartua Javies Banuelos Arthur Kluch](https://reader030.vdocument.in/reader030/viewer/2022033103/56649ebd5503460f94bc6e24/html5/thumbnails/4.jpg)
Design constraints and assumptions
• Current rules limit us to use a naturally aspirated 2.4L 90 V8 engine
• Our design is limited to the cylinder sleeve/liner and the piston
• Analysis performed at 19,250 RPM
![Page 5: FORMULA 1 RACING: SILICON NITRIDE ENGINE Levi Lentz Greg Berkeley Christian Igartua Javies Banuelos Arthur Kluch](https://reader030.vdocument.in/reader030/viewer/2022033103/56649ebd5503460f94bc6e24/html5/thumbnails/5.jpg)
![Page 6: FORMULA 1 RACING: SILICON NITRIDE ENGINE Levi Lentz Greg Berkeley Christian Igartua Javies Banuelos Arthur Kluch](https://reader030.vdocument.in/reader030/viewer/2022033103/56649ebd5503460f94bc6e24/html5/thumbnails/6.jpg)
Why Silicon Nitride
![Page 7: FORMULA 1 RACING: SILICON NITRIDE ENGINE Levi Lentz Greg Berkeley Christian Igartua Javies Banuelos Arthur Kluch](https://reader030.vdocument.in/reader030/viewer/2022033103/56649ebd5503460f94bc6e24/html5/thumbnails/7.jpg)
Here’s Why
Si3N4 Zinc Alloys Mg Alloys AluminumSintered-Reaction Bonded Sintered Hot Pressed Zamak 3 Zamak 5 AZ91A AZ91D 6061
Modulus of Elasticity 300 GPa 300 GPa 300 GPa 130 GPa 130 GPa 45 GPa 45 GPa 68.9 GPa
Shear Modulus 148 MPa No data found No data found 214 MPa 262 MPa 17 GPa 17 GPa 26 GPa
Fracture Toughness
5.0-8.0 MPa-sqrt(m)
7.5 MPa-sqrt(m)
4.5 MPa-sqrt(m)
12.3 MPa*sqrt(m)
2.1x10^7 N*m^-(3/2) no data found no data found 29 MPa-sqrt(m)
Thermal Expansion 3.4 microm/K 3.1 microm/K 3.2 microm/K 27 microm/K 27 microm/K
26 microm/m*K @ 20-100degC
Same as AZ91A
25.2 microm/m-Deg C
Thermal Conductivity 27 W/m-K 22 W/m-K 26 W/m-K 113 W/m*K 110 W/m*K
72W/m*K @ 100-300degC
Same as AZ91A 167 W/m-K
Thermal Shock Resistance
700 deltaT Deg-C
800 DeltaT Deg-C
700 DeltaT Deg-C
Density 3.31 g/cm3 3.24 g/cm3 3.2 g/cm3 6.6g/cm3 6.7g/cm3 1.81g/cm3 1.81g/cm3 2.7 g/cm3
Melting point 1500+ Deg-C 380-387 degC 380-386 degC 421 degC 421 degC 582-652 Deg-C
-Silicon Nitride [SN for short] has high strength, low thermal conductivity and expansion rates
-Other alloys have low melting points
![Page 8: FORMULA 1 RACING: SILICON NITRIDE ENGINE Levi Lentz Greg Berkeley Christian Igartua Javies Banuelos Arthur Kluch](https://reader030.vdocument.in/reader030/viewer/2022033103/56649ebd5503460f94bc6e24/html5/thumbnails/8.jpg)
MATERIAL ANALYSIS
![Page 9: FORMULA 1 RACING: SILICON NITRIDE ENGINE Levi Lentz Greg Berkeley Christian Igartua Javies Banuelos Arthur Kluch](https://reader030.vdocument.in/reader030/viewer/2022033103/56649ebd5503460f94bc6e24/html5/thumbnails/9.jpg)
Internal Pressure Variation
0.000000000 0.000500000 0.001000000 0.001500000 0.002000000 0.002500000 0.003000000 0.0035000000
0.5
1
1.5
2
2.5
3
3.5
Pressure vs. Time
Time (sec)
Pres
sure
(MPa
)
![Page 10: FORMULA 1 RACING: SILICON NITRIDE ENGINE Levi Lentz Greg Berkeley Christian Igartua Javies Banuelos Arthur Kluch](https://reader030.vdocument.in/reader030/viewer/2022033103/56649ebd5503460f94bc6e24/html5/thumbnails/10.jpg)
Cyclic Loading/Material Life
• Design factor will be Hoop-Stress ~10x larger than internal pressure
• • Nf=5.7e12• Cycles/race: 193e6• Huge Factor of Safety
1.00E+00 1.00E+05 1.00E+10 1.00E+15 1.00E+20 1.00E+251
10
100
1000
Stress vs Cycles to Failure
Number to Failure
Stre
ss A
mpl
itude
![Page 11: FORMULA 1 RACING: SILICON NITRIDE ENGINE Levi Lentz Greg Berkeley Christian Igartua Javies Banuelos Arthur Kluch](https://reader030.vdocument.in/reader030/viewer/2022033103/56649ebd5503460f94bc6e24/html5/thumbnails/11.jpg)
Thermal Stress
• Longitudinal stress of 480.8MPa
• Very low K value yields:• a=.05mm• Critical on the cylinder sleeve
![Page 12: FORMULA 1 RACING: SILICON NITRIDE ENGINE Levi Lentz Greg Berkeley Christian Igartua Javies Banuelos Arthur Kluch](https://reader030.vdocument.in/reader030/viewer/2022033103/56649ebd5503460f94bc6e24/html5/thumbnails/12.jpg)
Thermal Analysisext21 WQjmjm
dt
dE
extWQ Closed Steady State
![Page 13: FORMULA 1 RACING: SILICON NITRIDE ENGINE Levi Lentz Greg Berkeley Christian Igartua Javies Banuelos Arthur Kluch](https://reader030.vdocument.in/reader030/viewer/2022033103/56649ebd5503460f94bc6e24/html5/thumbnails/13.jpg)
Maximum PowermkN 279.0
s 60
rpm 19250 22shext
TWW
kW 4.562sh W
kW 4.562 3
2 shinin WQQ
kW 8.124,1 kW 2.687,1 outin QQ
m 005.0
m 0.01225 C 30 C 500 K W/m120
thickness
Area 2-1-1ambientinside
out
TTkQ
kW 138mat out, Q kW 6.987exh out, Q
33% Efficiency
Heat Transfer
![Page 14: FORMULA 1 RACING: SILICON NITRIDE ENGINE Levi Lentz Greg Berkeley Christian Igartua Javies Banuelos Arthur Kluch](https://reader030.vdocument.in/reader030/viewer/2022033103/56649ebd5503460f94bc6e24/html5/thumbnails/14.jpg)
m 005.0
m 0.01225 C 30 C 500 K W/m30
thickness
Area 2-1-1ambientinside
out
TTkQ
kW 5.34mat out, Q
kW 6.987exh out, Q
kW 1.022,1 kW 2.687,1 outin QQ
in
out
in
ext 1efficiencyQ
Q
Q
W
39.4%
![Page 15: FORMULA 1 RACING: SILICON NITRIDE ENGINE Levi Lentz Greg Berkeley Christian Igartua Javies Banuelos Arthur Kluch](https://reader030.vdocument.in/reader030/viewer/2022033103/56649ebd5503460f94bc6e24/html5/thumbnails/15.jpg)
Aluminum Piston FEA Results
Stress Analysis
![Page 16: FORMULA 1 RACING: SILICON NITRIDE ENGINE Levi Lentz Greg Berkeley Christian Igartua Javies Banuelos Arthur Kluch](https://reader030.vdocument.in/reader030/viewer/2022033103/56649ebd5503460f94bc6e24/html5/thumbnails/16.jpg)
Bottom View of Piston
![Page 17: FORMULA 1 RACING: SILICON NITRIDE ENGINE Levi Lentz Greg Berkeley Christian Igartua Javies Banuelos Arthur Kluch](https://reader030.vdocument.in/reader030/viewer/2022033103/56649ebd5503460f94bc6e24/html5/thumbnails/17.jpg)
Displacement Results
![Page 18: FORMULA 1 RACING: SILICON NITRIDE ENGINE Levi Lentz Greg Berkeley Christian Igartua Javies Banuelos Arthur Kluch](https://reader030.vdocument.in/reader030/viewer/2022033103/56649ebd5503460f94bc6e24/html5/thumbnails/18.jpg)
Bottom View
![Page 19: FORMULA 1 RACING: SILICON NITRIDE ENGINE Levi Lentz Greg Berkeley Christian Igartua Javies Banuelos Arthur Kluch](https://reader030.vdocument.in/reader030/viewer/2022033103/56649ebd5503460f94bc6e24/html5/thumbnails/19.jpg)
Silicon Nitride FEA Results
Stress Analysis
![Page 20: FORMULA 1 RACING: SILICON NITRIDE ENGINE Levi Lentz Greg Berkeley Christian Igartua Javies Banuelos Arthur Kluch](https://reader030.vdocument.in/reader030/viewer/2022033103/56649ebd5503460f94bc6e24/html5/thumbnails/20.jpg)
Displacement Results
![Page 21: FORMULA 1 RACING: SILICON NITRIDE ENGINE Levi Lentz Greg Berkeley Christian Igartua Javies Banuelos Arthur Kluch](https://reader030.vdocument.in/reader030/viewer/2022033103/56649ebd5503460f94bc6e24/html5/thumbnails/21.jpg)
Bottom View
![Page 22: FORMULA 1 RACING: SILICON NITRIDE ENGINE Levi Lentz Greg Berkeley Christian Igartua Javies Banuelos Arthur Kluch](https://reader030.vdocument.in/reader030/viewer/2022033103/56649ebd5503460f94bc6e24/html5/thumbnails/22.jpg)
Manufacturing Processes
There are a few methods in use today to manufacture SN• Hot Pressed SN: Heated to 1800 Deg-C and pushed through a
die at 40 MPa of pressure. Only simple shapes possible and expensive.
• Reaction Bonded SN: Cheaper and capable of complex shapes, but inferior material.
• Sintered SN: Best material properties, but expensive and high shrink rate (17-21%). Extra machining needed.
• Sintered and Reaction Bonded SN: A mating of RBSN and SSN. High quality material, cheaper and capable of complex shapes with little extra machining. Fabrication method of choice.
![Page 23: FORMULA 1 RACING: SILICON NITRIDE ENGINE Levi Lentz Greg Berkeley Christian Igartua Javies Banuelos Arthur Kluch](https://reader030.vdocument.in/reader030/viewer/2022033103/56649ebd5503460f94bc6e24/html5/thumbnails/23.jpg)
![Page 24: FORMULA 1 RACING: SILICON NITRIDE ENGINE Levi Lentz Greg Berkeley Christian Igartua Javies Banuelos Arthur Kluch](https://reader030.vdocument.in/reader030/viewer/2022033103/56649ebd5503460f94bc6e24/html5/thumbnails/24.jpg)
What is Sintered Reaction Bonded Silicon Nitride? (SRBSN for short!)
• Silicon powder packed into a mold, seeded with Beta-SN particles and mixed with
sintering additives (Y2O3–MgSiN2 and Li2O).
• Powder then undergoes a nitriding process creating SN
• Sintering is then applied to further increase material strength and density, but a little
material shrinkage occurs (10-12%).
![Page 25: FORMULA 1 RACING: SILICON NITRIDE ENGINE Levi Lentz Greg Berkeley Christian Igartua Javies Banuelos Arthur Kluch](https://reader030.vdocument.in/reader030/viewer/2022033103/56649ebd5503460f94bc6e24/html5/thumbnails/25.jpg)
Benefits of Beta-SN seeding
-Increased fracture strength
-Increased fracture toughness
![Page 26: FORMULA 1 RACING: SILICON NITRIDE ENGINE Levi Lentz Greg Berkeley Christian Igartua Javies Banuelos Arthur Kluch](https://reader030.vdocument.in/reader030/viewer/2022033103/56649ebd5503460f94bc6e24/html5/thumbnails/26.jpg)
![Page 27: FORMULA 1 RACING: SILICON NITRIDE ENGINE Levi Lentz Greg Berkeley Christian Igartua Javies Banuelos Arthur Kluch](https://reader030.vdocument.in/reader030/viewer/2022033103/56649ebd5503460f94bc6e24/html5/thumbnails/27.jpg)
What's the cost?
• High materials cost and specialized fabrication methods are
expensive.• Fabrication time measures in hours because
of special material preparations.• Estimated cost per SN part will be $450 per
kg.• Pistons will cost about $650 each.
![Page 28: FORMULA 1 RACING: SILICON NITRIDE ENGINE Levi Lentz Greg Berkeley Christian Igartua Javies Banuelos Arthur Kluch](https://reader030.vdocument.in/reader030/viewer/2022033103/56649ebd5503460f94bc6e24/html5/thumbnails/28.jpg)
Future Design Considerations
• Silicon Nitride Works• FIA Rules• Aluminum-type material• Easier to manufacture• Similar thermal-properties