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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.