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Engine Reliability

Engine Reliability

3 days

MOT/FIMOT-E

Request an in-house session

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Who should attend?

Learning Objectives

Sessions

This course is not scheduled.

Who should attend?

Audience

- Engineers and technical staff involved in design or testing, who need to know damaging and failure processes of engine components.
- People of Quality department or aftersales technical analysis may also be interested.

Level

Advanced

This course provides an understanding of the physical phenomena causing engine parts damage, the phenomena being thermal, mechanical, thermo-mechanical or tribologic ones. The theoretical aspect is punctuated with examples of damaged parts - pictures or real parts.

Learning Objectives

Upon completion of the course, participants will be able to:
diagnose the possible origin of a damage problem of an engine component,
talk with tests and laboratory specialists to direct parts analysis and the validation tests to be performed,
suggest solutions likely to solve the problem.

Course Content

Engine parts damage modes

0.75 day

Mechanical engineer tools, statistical aspects of reliability.
Thermal damage: coking, mechanical characteristic losses, intercrystalline corrosion, burnout, creeping, melting, lubricant viscosity drop.
Mechanical damage: plastic distortion, unshrinking, fracture or fatigue failure, vibration impact.
Thermo-mechanical damage: stresses caused by constrained metal expansion.
Tribologic ones: lubrication parameters, stribeck curve, pitting, micro-reptation, loosening, fretting/micro-welding, abrasive wear, adhesive wear, erosive wear, cavitation, scuffing, seizing, stick-slip.

Mobile parts damage

0.75 day

Conrods: failure modes, almost static stresses, dynamic stresses, buckling, screws resistance.
Crankshaft: quasi-static (gas pressures and inertia) and dynamic (flexion and torsion) stresses, strengthening treatments, roller-burnishing, dimensioning calculations, fatigue tests.
Bushing damage modes: fatigue, wear, cavitation wear, abrasive wear, scale and pollution wear, micro-welding, seizing.
Piston: distortions, ring sticking, skirt crush, seizing, stresses in the pin bosses.

Fixed parts damage

0.5 day

Ignition pressure and manufacturing related mechanical stresses (assemblies, shrink fitting, tightening).
Thermal stresses and thermo-mechanical constraints.
Cylinder head: cracking, materials, fire face behavior and solutions for its resistance, other critical points.
Exhaust manifold: mechanical and thermal stresses, materials, failures found, solutions.
Cylinder head gasket: stresses, failures, influence of the cylinder head and crankcase cylinders distortions, solutions.

Cooling

0.5 day

Heat transfers by conduction, convection, radiation, phase change. Thermal balance.
Thermics and engine cooling: levels of temperatures reached, critical points, cooling fluid circulation in the block and the cylinder head.
External cooling circuit: permanent branch, thermally regulated branch, pump, exchangers, thermostat, ventilating, cooling fluid, dimensioning.
Thermal measure means: thermo-couples, thermistors, flux meter, infrared pyrometry.

Lubrication

0.5 day

Lubricant cleanliness and consequences on wear.
Engine oil rheological behavior and change of properties in service:
Oxidation thickening, soot, black sludge and consequences on cold starting.
Viscosity decrease by polymer shearing or by dilution and consequences on warm engine.
Thermal and oxidation stability: cracking, thickening, deposits.
Timing lubrication.

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Ways & Means

Interactive training using a number of real components, pictures and videos.
Real life analysis of failures of components, search for origin of failures, description of the deteriorating process.
It is possible to manage this exercise on a component previously proposed by a learner, with a description of use conditions.