scholarly journals Study of failures of reciprocating medium-speed diesel engines

2020 ◽  
Vol 2020 (3) ◽  
pp. 64-70
Author(s):  
Irina Nikolaevna Ruban ◽  
Vladimir Pavlovich Bulgakov
Keyword(s):  
Wear Resistance ◽  
Cast Iron ◽  
Failure Rate ◽  
Diesel Engines ◽  
Gray Cast Iron ◽  
Normal Operation ◽  
Gray Cast ◽  
Engine Operation ◽  
Normal Period ◽  
Cavitation Wear

The article is focused upon the problems of reciprocating diesel engines. The main reason for the failure of cylinder-piston group (CPG) parts is insufficient strength, wear resistance, and resistance of the metal structure to vibration. There are studied the following periods of engine operation: running-in period; period of normal operation; period of intensive wear. In the burn-in period, the main cause of CPG failures is scuffing, when finger breaking or ring groove chipping take place. Sudden failures during normal operation occur due to the wear of the bushings to the limit size. In the third period of intensive wear the main cause of metal failures is the ultimate wear by cavitation erosion and breakage of the bushing collar. The block diagram of the CPG system with serial connection of elements is given. The rate of CPG failures is illustrated depending on the time of operation. It has been found that the failure rate during the running-in period due to scuffing is reduced because of stabilization of the structure, dimensions and mechanical properties of the piston at operating temperatures (300–350°C). The failure rate of the normal period of operation depends on the increase in the abrasive wear resistance of the metal of bushings, increased hardness, due to the replacement of gray cast iron with lamellar graphite by gray cast iron with vermicular graphite or by high-strength cast iron with spherical graphite inclusions. There are listed the positive and negative qualities of aluminum alloys in comparison with cast iron. Variants of damage to cylinder liners are considered in detail. The most dangerous defect in the bushing is the cracks in the upper liner collar, as a result of which about 40% of the cylinder bushings must be replaced. The formulas for calculating the actual wear rate of the CPG parts during the first (end of warranty periods), medium and major overhauls are given. The failure rate of the last period of operation (intensive wear) is reduced by reducing vibration in the CPG system, reducing the amplitude of forced vibrations and reducing the size of the thermal gap between the sleeve and the piston, increasing the rigidity of the sleeve. The rate of cavitation wear of modernized and conventional bushings is determined, the influence of the bushing stiffness on cracks under the shoulder and on cavitation wear up to the maximum permissible thickness is considered.

Experimental Methods for NiCrBSi-WC Cladding on Gray Cast Iron Trim Cutter Die

2015 ◽  
Vol 761 ◽  
pp. 298-302
Author(s):  
N.I.S. Hussein ◽  
S.R. Kamarul ◽  
Mohamad Nizam Ayof
Keyword(s):  
Wear Resistance ◽  
Cast Iron ◽  
Gray Cast Iron ◽  
Rejection Rate ◽  
Cutting Edge ◽  
Gray Cast ◽  
Filler Material ◽  
Burr Formation ◽  
Resistant Material ◽  
Wear Resistant

The wear on the cutting edge of the gray cast iron trim cutter die will result in the burr formation on the trimmed blanks. This will increase the rejection rate, and hence, decreasing the efficiency of the production. By applying a wear resistant material, the wear rate on the cutting edge of the die is believed to be minimized. In this paper, the methodology of the experiment on the cladding process using gas metal arc as the heat source, and NiCrBSi-WC as the filler material on gray cast iron substrate is presented. NiCrBSi-WC is chosen as the filler material because of its outstanding wear resistance characteristic. Furthermore, it is a popular choice as a wear resistant material in various types of industry. The purpose of the planned experiment is to maximize the wear resistance of the trim cutting die. It is also a fraction of the case study based on the parts production in the automotive industry in Malaysia.

Influence of Orientations of Bionic Unit Fabricated by Laser Remelting on Fatigue Wear Resistance of Gray Cast Iron

2015 ◽  
Vol 24 (6) ◽  
pp. 2511-2520 ◽  
Author(s):  
Zhi-Kai Chen ◽  
Ti Zhou ◽  
Hai-feng Zhang ◽  
Wan-shi Yang ◽  
Hong Zhou
Keyword(s):  
Wear Resistance ◽  
Cast Iron ◽  
Gray Cast Iron ◽  
Gray Cast ◽  
Laser Remelting ◽  
Fatigue Wear

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.

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

Microstructure and tribological properties of gray cast iron specimens coated by aluminizing, boronizing, chromizing and siliconizing

2012 ◽  
Vol 1516 ◽  
pp. 115-120 ◽  
Author(s):  
T. Murakami ◽  
K. Matsuzaki ◽  
Y. Gomi ◽  
S. Sasaki ◽  
H. Inui
Keyword(s):  
Wear Resistance ◽  
Cast Iron ◽  
Tribological Properties ◽  
Gray Cast Iron ◽  
Steel Ball ◽  
Gray Cast ◽  
Iron Plate ◽  
Aisi 52100 ◽  
Alpha Olefin ◽  
Aisi 52100 Steel

ABSTRACTIn this study, aluminized, boronized, chromized and siliconized gray cast iron plate specimens were prepared, and their microstructures and tribological properties were investigated. The surfaces of the aluminized, boronized, chromized and siliconized specimens mainly consisted of FeAl, Fe2B, (Cr, Fe)23C6 and FeSi phases, respectively. Also, the surface of the boronized specimen exhibited the highest microvickers hardness of all the specimens. The aluminized, boronized and chromized specimens exhibited friction coefficients as low as the non-coated specimens when sliding against AISI 52100 steel ball specimens in poly-alpha-olefin. In addition, the boronized and chromized specimens exhibited much higher wear resistance than the non-coated specimens.

scholarly journals Effect of silicon carbide modifiers on the physical-mechanical properties of gray cast iron and cast iron with spheroidal graphite

2021 ◽  
Vol 340 ◽  
pp. 01006
Author(s):  
Vladimir A. Poluboyarov ◽  
Anatoliy N. Cherepanov ◽  
Viktor A. Kuznetsov ◽  
Zoya A. Korotaeva ◽  
Alexander A. Zhdanok
Keyword(s):  
Mechanical Properties ◽  
Silicon Carbide ◽  
Wear Resistance ◽  
Cast Iron ◽  
Gray Cast Iron ◽  
Term Treatment ◽  
Gray Cast ◽  
Spheroidal Graphite ◽  
Short Term Treatment ◽  
Maximal Increase

The influence of mechanochemically produced modifiers on the properties of cast iron at out-of-furnace modification has been studied. Short-term treatment in mechanochemical activators makes it possible to produce composite modifiers, which are wetted with iron melts, are uniformly distributed therein and effectively influence the crystallization processes. The effect of a modifier based on silicon carbide and chromium (as a protector metal) on the physical-mechanical properties of gray cast-iron and cast-iron with spheroidal graphite is considered. The introduction of SiC in the amount of 0.01-0.1 wt.% into gray cast iron causes the formation of mainly perlitic structure and, as a consequence, an increase in strength, hardness and wear resistance. For SiC content 0.1 wt.%, the tensile strength of GG-15 samples increased by 22.7%, GG-25 by 8%. The maximal increase in the hardness is observed for SiC concentration: for GG-15 – 0.1, for GG-25 – 0.01 wt.%. The GG-25 sample with 0.1 wt.% SiC exhibited the highest wear resistance. The introduction of SiC (0.01 – 0.1 wt.%) into cast iron with spheroidal graphite causes an increase in ferrite content, which promotes a substantial increase in impact viscosity and wear resistance (the highest wear resistance is observed with the introduction of 0.05 wt.% SiC).

scholarly journals Increasing wear resistance of the protective sleeve of the centrifugal pump made of gray cast iron by surface hardening

2021 ◽  
pp. 103
Author(s):  
Nataliia Lalazarova ◽  
Оlga Afanasieva ◽  
Olena Popova ◽  
Oleksiy Dmytrenko
Keyword(s):  
Wear Resistance ◽  
Cast Iron ◽  
High Frequency ◽  
Gray Cast Iron ◽  
Operating Time ◽  
Hardened Layer ◽  
Gray Cast ◽  
Centrifugal Pumps ◽  
Surface Quenching ◽  
Surface Induction

One of the weak spots that reduce the guaranteed operating time of centrifugal pumps is the assembly that includes the seal and protective sleeves. The main purpose of the bushings in the rotor kit is to protect the shaft from corrosion, erosion and wear. The sleeve operates under abrasive wear conditions by packing elements and abrasive particles that get into the liquid pumped by the pump. The protective sleeves made of gray cast iron do not meet the service life in connection with accelerated surface wear. Goal. The purpose of the work is to ensure high wear resistance of cast iron pump parts by heat treatment. Method. The chemical composition was determined on a portable laser analyzer Laser Z200 C +. The structure was studied using an optical microscope. The wear was investigated by the roller-block method on a friction machine. Surface quenching was carried out with a high-frequency lamp generator in a single-turn inductor. Results. The microstructure of gray cast iron as cast consists of pearlite, ferite, double phosphide eutectic and inclusions of lamellar graphite. Microhardness of small-lamellar pearlite is Н50 = 1550–2220 MPa, microhardness of phosphide eutectic is Н50 = 6500–8000 MPa. Surface induction quenching by high-frequency currents followed by low tempering is an effective way to increase the wear resistance of cast iron products of small cross-section and does not cause warping. Cast iron for surface quenching should have a pearlite structure, and graphite should be contained in the form of small inclusions. The optimal heating temperature for induction hardening was determined as 900 °С, which made it possible to obtain the microstructure of the hardened layer – martensite, double phosphide eutectic and graphite. Scientific novelty. The developed modes of surface quenching make it possible to preserve a double phosphide eutectic in the structure of the surface layer, which makes it possible to obtain high hardness and wear resistance of the hardened layer. Practical significance. Surface induction quenching with low tempering of cast gray iron increased its wear resistance by 2,4 times. The previous normalization had practically no effect on the durability of cast iron, since its structure contains less than 10% ferrite.

scholarly journals Effects of quench-tempering and laser hardening treatment on wear resistance of gray cast iron

2020 ◽  
Vol 9 (4) ◽  
pp. 8163-8171 ◽  
Author(s):  
Bingxu Wang ◽  
Yuming Pan ◽  
Yu Liu ◽  
Na Lyu ◽  
Gary C. Barber ◽  
...  
Keyword(s):  
Wear Resistance ◽  
Cast Iron ◽  
Gray Cast Iron ◽  
Laser Hardening ◽  
Gray Cast ◽  
Hardening Treatment

DURA-BAR G2

Alloy Digest ◽  
2020 ◽  
Vol 69 (1) ◽  
Keyword(s):  
Wear Resistance ◽  
Cast Iron ◽  
Physical Properties ◽  
Tensile Properties ◽  
Gray Cast Iron ◽  
Vibration Damping ◽  
Gray Cast ◽  
Damping Properties ◽  
Continuous Cast ◽  
Cast Products

Abstract Dura-Bar G2 is a gray cast iron bar is used for continuous cast products. It is a good fit for a variety of applications due to its good machinability, wear resistance, and vibration damping properties. This datasheet provides information on composition, physical properties, hardness, elasticity, and tensile properties. It also includes information on machining. Filing Code: CI-65. Producer or source: Charter Dura-Bar, Inc.

Effect of the structure and hardness of gray cast iron on its wear resistance

1970 ◽  
Vol 6 (6) ◽  
pp. 515-517
Author(s):  
V. V. Spasskii ◽  
I. V. Patalakha ◽  
P. D. Kurochkin ◽  
A. A. Chernyi
Keyword(s):  
Wear Resistance ◽  
Cast Iron ◽  
Gray Cast Iron ◽  
Gray Cast
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