Al-Si piston alloy behavior under combined mechanical and thermal cyclic loading with superimposed high-frequency thermal cycling
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Uwe Gutermuth
Abstract
On pistons for diesel direct injection engines, the thermally high loaded bowl rim is exposed to high-cycle mechanical and high-cycle thermal loading during each combustion event in addition to the thermal cycling induced by variable engine loading, e. g. between idle and full load. This combined loading at various overall temperatures during engine operation contributes to material damage and finally to a limited service life. In the past, the high-cycle thermal loading has neither been experimentally investigated nor incorporated into a numerical model for lifetime estimation. The work described in this paper deals with the setup of an experimental test procedure on samples taken from components for which the effects of slow temperature cycling, fast temperature cycling and mechanical cyclic fatigue loading can be combined in different ratios. The aim of the investigation is to characterize the sample lifetime with respect to varied test conditions in order to differentiate alloy- or process-related material variations in support of process and material development.
Kurzfassung
Es wurde ein innovatives Prüfverfahren entwickelt und zum Patent angemeldet, das die mechanische und thermische Beanspruchung an intermittierend thermisch beaufschlagten Komponenten realitätsnah einer Werkstoffprobe bzw. einer direkt aus dem Bauteil entnommenen Probe aufprägt. Erstmals wird der zusätzliche Einfluss der oberflächennahen hochzyklischen thermischen Beanspruchung auf die Gesamtschädigung im Versuch nachgebildet und nachgewiesen, dass sich hierdurch die Lebensdauer gegenüber einer reinen TMF+HCF-Belastung signifikant reduziert. Die Prüfmethode erlaubt in kurzer Zeit einen Vergleich zwischen verschiedenen Legierungsvarianten zu erstellen und liefert ein Ranking, das mit motorischen Ergebnissen korreliert. Im Vergleich zum Motor fehlt in der vorgestellten Prüfmethode noch die Abbildung der bei der Verbrennung ablaufenden chemischen Prozesse; allerdings ist zu erwarten, dass dieser Einfluss auf die Lebensdauer für Aluminiumwerkstoffe gering bis vernachlässigbar sein wird. Für eisenbasierte Werkstoffe kann dagegen die Oxidation bzw. Zunderbildung nicht vernachlässigt werden.
References
1 MAHLE GmbH (Ed.): Pistons and engine testing, 2nd Edition, Springer Fachmedien, Wiesbaden, Germany (2016)Suche in Google Scholar
2 FVV Final Report of Research Project 987: Damage and lifetime, FVV-Heft 980, Frankfurt/Main, Germany (2013) (in German)Suche in Google Scholar
3 FVV Final Report of Research Project 750: Non-stationary thermal and mechanical loading in engines, FVV-Heft 765, Frankfurt/Main, Germany (2002) (in German)Suche in Google Scholar
4 C. P.Ding, R.Honza, B.Böhm: Simultaneous measurement of flame impingement and piston surface temperatures in an optically accessible spark ignition engine, Applied Physics B123 (2017), No. 11010.1007/s00340-017-6694-ySuche in Google Scholar
5 U.Gutermuth, W.Ißler, D.Schuster, Procedure to simulate operating conditions of an ICE piston particularly at the combustion bowl, Patent pending. DE102017203490, filed 03.03.2017, (in German, German title: Verfahren zum Simulieren von Betriebsbedingungen eines Kolbens, insbesondere im Bereich der Kolbenmulde, in einer Brennkraftmaschine)Suche in Google Scholar
© 2018, Carl Hanser Verlag, München
Artikel in diesem Heft
- Inhalt/Contents
- Contents
- Fachbeiträge/Technical Contributions
- Bending deformation and indentation hardness of electrochemically deposited nanocrystalline nickel-iron alloys
- Al-Si piston alloy behavior under combined mechanical and thermal cyclic loading with superimposed high-frequency thermal cycling
- Porosity of LMD manufactured parts analyzed by Archimedes method and CT
- Structure and mechanical properties of ADC 12 Al foam-polymer interpenetrating phase composites with epoxy resin or silicone
- Strength changes of 40 Cr steel subjected to cyclic torsion below the fatigue limit
- Auxetic aluminum sheets in lightweight structures
- Effect of thickness on the fracture toughness of high strength steel for gas well casings
- Effect of laser welding speed on the weld quality of a 5A06 aluminum alloy
- Correlation of ultrasound velocity with physico-mechanical properties of Jodhpur sandstone
- Etching behavior of ZnO:Ga thin films
- Repair of an aluminum plate with an elliptical hole using a composite patch
- Impression creep behavior of extruded ZK60 and ZK60+1 %Y magnesium alloys
- Experimental study for the bearing capacity calculation of concrete expanded plates in squeezed branch piles
- Mechanical properties and microstructure of autoclaved green UHPC blended with granite stone powders
- Mechanical properties and microstructure of glass carbon hybrid composites
Artikel in diesem Heft
- Inhalt/Contents
- Contents
- Fachbeiträge/Technical Contributions
- Bending deformation and indentation hardness of electrochemically deposited nanocrystalline nickel-iron alloys
- Al-Si piston alloy behavior under combined mechanical and thermal cyclic loading with superimposed high-frequency thermal cycling
- Porosity of LMD manufactured parts analyzed by Archimedes method and CT
- Structure and mechanical properties of ADC 12 Al foam-polymer interpenetrating phase composites with epoxy resin or silicone
- Strength changes of 40 Cr steel subjected to cyclic torsion below the fatigue limit
- Auxetic aluminum sheets in lightweight structures
- Effect of thickness on the fracture toughness of high strength steel for gas well casings
- Effect of laser welding speed on the weld quality of a 5A06 aluminum alloy
- Correlation of ultrasound velocity with physico-mechanical properties of Jodhpur sandstone
- Etching behavior of ZnO:Ga thin films
- Repair of an aluminum plate with an elliptical hole using a composite patch
- Impression creep behavior of extruded ZK60 and ZK60+1 %Y magnesium alloys
- Experimental study for the bearing capacity calculation of concrete expanded plates in squeezed branch piles
- Mechanical properties and microstructure of autoclaved green UHPC blended with granite stone powders
- Mechanical properties and microstructure of glass carbon hybrid composites
