Cylinder Liner in Ductile Cast Iron for High Loaded Combustion Diesel Engines

2011 ◽  
Author(s):  
Edney Deschauer Rejowski ◽  
Edmo Soares ◽  
Ingo Roth ◽  
Steffen Rudolph
Keyword(s):  
Mechanical Properties ◽  
Cast Iron ◽  
Wall Thickness ◽  
Diesel Engines ◽  
Ductile Iron ◽  
Gray Cast Iron ◽  
Young Modulus ◽  
Gray Cast ◽  
Cast Material ◽  
Cylinder Liners

With the increase of combustion loading and the trend to reduce engine size, there is a need for thinner but stronger wet cylinder liners. While most of the current cylinder liners are made of gray cast iron, due to its good tribological behavior, machinability performance and competitive price, alternative casting materials like compact graphite iron, ductile iron and even steel are being considered to cover the future engine demands. In this paper, a new ductile iron (DI) cast material for wet cylinder liners is presented. The material has about 60 and 70% higher limits respectively for tensile stress and fatigue resistance as compared to conventional gray cast irons, but without penalty on the tribological properties. There is also a potential improvement to avoid cavitation on the outside surface due to its higher young modulus, which also equates to a higher stiffness. The tested cylinder liners were induction hardened on the running surface and a slide hone process was used to improve wear and scuffing resistance. The liners were tested in a HDD engine with PCP of 245 bar and showed similar wear as observed with conventional cylinder liners of gray cast iron material. The DI cylinder liners were also tested in an abusive scuffing engine test without any concern. The improved mechanical properties of the described new DI material introduce possibilities to reduce liner wall thickness or increase specific output. The preliminary evaluation in this paper showed that this new material is feasible for HDD diesel engines with PCP up to 250 bar. In cases that the customer needs to increase the bore diameter for output reasons there is the potential to reduce the liner wall thickness up to 25% based on high mechanical properties (UTS, Young Modulus and fatigue strength). In both cases, it’s recommended a FEA analysis to support the new component design.

Cylinder Liner in Ductile Cast Iron for High Loaded Combustion Diesel Engines

2012 ◽  
Vol 134 (7) ◽  
Author(s):  
Edney Deschauer Rejowski ◽  
Edmo Soares ◽  
Ingo Roth ◽  
Steffen Rudolph
Keyword(s):  
Mechanical Properties ◽  
Cast Iron ◽  
Wall Thickness ◽  
Diesel Engines ◽  
Ductile Iron ◽  
Gray Cast Iron ◽  
Gray Cast ◽  
Preliminary Evaluation ◽  
Cast Material ◽  
Cylinder Liners

With the increase of combustion loading and the trend to reduce engine size, there is a need for thinner but stronger wet cylinder liners. While most of the current cylinder liners are made of gray cast iron, due to its good tribological behavior, machinability performance, and competitive price, alternative casting materials such as compact graphite iron, ductile iron, and even steel are being considered to address future engine demands. In this paper, a new ductile iron (DI) cast material for wet cylinder liners is presented. The material has about 60 and 70% higher limits, respectively, for tensile stress and fatigue resistance as compared to conventional gray cast irons, but without a penalty on the tribological properties. There is also a potential improvement to avoid cavitation on the outside surface due to its higher young modulus, which also equates to a higher stiffness. The tested cylinder liners were induction hardened on the running surface and a slide hone process was used to improve wear and scuffing resistance. The liners were tested in a heavy duty diesel (HDD) engine with a peak cylinder pressure (PCP) of 245 bar and showed similar wear as observed with conventional cylinder liners of gray cast iron material. The DI cylinder liners were also tested in an abusive scuffing engine test without any concern. The improved mechanical properties of the described new DI material introduce possibilities to reduce the liner wall thickness or increase specific output. The preliminary evaluation in this paper showed that this new material is feasible for HDD diesel engines with a PCP up to 250 bar. In cases where the customer needs to increase the bore diameter for output reasons there is the potential to reduce the liner wall thickness by up to 25% based on high mechanical properties (UTS, Young’s modulus and fatigue strength). In both cases, a FEA analysis to support the new component design is recommended.

Influence of chemical composition and microstructure of gray cast iron on wear of heavy duty diesel engines cylinder liners

Wear ◽  
2007 ◽  
Vol 263 (7-12) ◽  
pp. 1158-1164 ◽  
Author(s):  
J. Keller ◽  
V. Fridrici ◽  
Ph. Kapsa ◽  
S. Vidaller ◽  
J.F. Huard
Keyword(s):  
Cast Iron ◽  
Chemical Composition ◽  
Diesel Engines ◽  
Gray Cast Iron ◽  
Gray Cast ◽  
Heavy Duty ◽  
Heavy Duty Diesel ◽  
Cylinder Liners

Teknologi Inokulasi Besi Cor Kelabu FC-250 Untuk Mencegah Pengerasan Pada Dove Tale Produk Ragum Tipe 125

2019 ◽  
Vol 16 (2) ◽  
Author(s):  
Amin Suhadi ◽  
Seodihono
Keyword(s):  
Mechanical Properties ◽  
Cast Iron ◽  
Treatment Process ◽  
Gray Cast Iron ◽  
Spare Parts ◽  
Gray Cast ◽  
Micro Structure ◽  
Control Factors ◽  
Seed Inoculation ◽  
Casting Industry

Production technology of metal casting industry in Indonesia needs to be improved, especially in the manufacturing of spare parts and box engine made of gray cast iron which has various wall thick such as dove tale construction. Microstructure of gray cast iron is influenced by cooling rate during casting, chemical composition and melting treatment process (inoculation). The part which has the thinnest thickness has the fastest cooling therefore, the grain boundary is smaller compared to other section. As a result this part has highest hardness and difficult to be machined. This research is conducted to solve this problem by modifying melting and solidification treatment process. The research starting from micro structure analysis, composition and mechanical properties tests on the product, and then conducting modification treatment through Taguchi method approach. Experimental results obtained show that the best level settings to control factors which affect to the uniformity of the microstructure and mechanical properties in gray cast iron is the addition of seed inoculation super ® 75, as much as 0.25% with the method of inoculation material entering into the Transfer Ladle.Teknologi produksi pada industri pengecoran di Indonesia masih membutuhkan perbaikan terutama dalam pembuatan komponen mesin perkakas dan peralatan pabrik yang terbuat dari besi tuang kelabu yang mempunyai variasi ketebalan yang besar seperti konstruksi ekor burung (dove tale). Pada pengecoran, struktur mikro dari besi tuang kelabu sangat dipengaruhi oleh kecepatan pendinginan, komposisi kimia dan proses perlakuan pada logam cair (inokulasi). Bagian yang mempunyai ukuran paling tipis mempunyai kecepatan pendinigan paling tinggi karena itu ukuran butirnya jauh lebih kecil dari bagian lain, akibatnya bagian ini mempunyai kekerasan lebih tinggi dan sulit dilakukan pengerjaan mesin. Penelitian ini bertujuan untuk memperbaiki hal ini yang terjadi pada dove taledengan cara memodifikasi proses perlakuan pada cairan besi dan proses pendinginan. Penelitian dimulai dari analisa struktur mikro, pengujian komposisi kimia, pengujian sifat mekanis pada produk kemudian dilakukan modifikasi menggunakan pendekatan metode statistik Taguchi. Hasil penelitian menunjukkan bahwa pengaturan terbaik yang dapat diperoleh untuk mendapatkan keseragaman struktur mikro dan sifat mekanis pada pengecoran besi tuang kelabu adalah penambahan seed inoculation super ® 75, sebesar 0.25% dengan metode pemasukan inokulasi kedalam Ladle pengangkut logam cair.Keywords: carbon, micro structure, hardness, inoculation

scholarly journals Influence of Microscopic Effects on the Static Tensile Strength of Gray Cast Iron HT200 Specimens

2021 ◽  
Vol 2021 ◽  
pp. 1-9
Author(s):  
L. Fan ◽  
H. B. Hu ◽  
X. S. Tang ◽  
J. J. He ◽  
W. Chen
Keyword(s):  
Cast Iron ◽  
Energy Density ◽  
Fracture Process ◽  
Gray Cast Iron ◽  
Static Strength ◽  
Gray Cast ◽  
Zone Model ◽  
Cast Material ◽  
Crack Growth Model ◽  
Density Zone

Gray cast iron HT200 material is a kind of pearlitic gray cast iron. Flake graphite in the gray cast iron greatly destroys the integrity of the matrix and affect the static strength. The influence of microscopic effects on the tensile static strength of gray cast iron HT200 specimens is investigated. The microstructures are observed by the scanning electron microscope. The failure tests are done under the static loads for the cylinder specimens of gray cast iron HT200. Then, an energy density zone (EDZ) model is applied to the simulation of the fracture process of the specimens. The energy density zone model is a macro/micro-trans-scale crack growth model that can depict a fracture process from an initial microdefect at the microscale to the final break at the macroscale. Three scale transitional functions as well as the size of the initial microdefect in the model represent the microscopic effects in a fracture process. Three scale transitional functions are speculated in view of the physical failure mechanisms. Two other material parameters in the model are determined from the test data. Thereby, the fracture process of gray cast iron specimens is numerically simulated, and the static strength values are calculated. The calculated values of static strength of gray cast iron specimens are identical to the test values. It is seen that the energy density zone model can accurately describe a fracture process of brittle materials like gray cast iron. In addition, the calculated results show that the microscopic effects did affect the static strength of gray cast material.

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