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Figure 2 showing the accepted emissions of soot PM and NOx depending on legislations [9].
b. Problem Statement:
The problem focused by the researcher in this study is to investigate the root causes of
wear, in the exhaust valves of a heavy-duty, natural-gas dedicated, Internal
Combustion engine.
The increasing demands from environmental legislations and the need to
conserve fossil fuels are changing the conditions that, the valve system is exposed to
in heavy duty engines. The use of natural gas as an alternate to run these heavy duty
engines resulted in increased pressures, higher temperatures and lower amounts of
soot which could build up a protective film, are some of the increasing challenges
which the system has to endure.
This study will help in identifying the key reasons of failure of the exhaust
valves, which ultimately resulted in an increase in the frequency of top-end over-
hauling of the engines of natural gas operated engines.
c. Objectives:
The main objective of this research is to investigate the type, mechanism and sources
of wear, which lead to failure of some specific exhaust valves of a Natural gas
dedicated I.C engine. So the sub-objectives of this research can be defined as:
To study the micro-structure and fracture surface of failed exhaust valves
specimens, using the SEM and contrasting that microstructure with that of a
new exhaust valve specimen.
To find out the structure, phases, crystallographic characteristics and chemical
composition of the solid particles deposited on the face of the exhaust valve
using X-ray Diffraction XRD
To conclude and relate to the different micro-structural data acquired by
various techniques, to know the causes of wear so as to avoid such wear and
failures in future.
The exhaust valve and its seat insert wear have significant effects on the engine
performance and also failure of the exhaust valve might result in the machine
downtime which will certainly effect the operations. Therefore, investigation of the
relationship between the exhaust valve, the seat insert wear and the cause of the wear
is a much needed requirement.
The benchmarking of microstructures of failed valves v/s new valves revealed
that the size of grains, grain boundaries, and distribution of carbide particles across
the material matrix is affected by high temperature conditions and the effects are more
severe for exhaust valves [6]. Exhaust valves are exposed to thermal stress more than
intake valve because intake valve are virtually cooled by in-flowing fresh air.
However burnt gases have very high temperature in the range of 800 - 10000C
because of this frequency of failure of exhaust valve is higher than inlet valve. The
wear mechanism in exhaust valves of such heavy duty engines has been found to be a
combination of oxidation and adhesive wear [7].
Figure showing: A) % change in the micro structure of new exhaust valve vs. failed exhaust valve
B) % change in the micro structure of failed exhaust valves vs. failed inlet valves [7].
The different test variables needed to fully co-relate the engine performance to
exhaust valve and valve seat operation include: the combustion pressure and
temperature, the running speed of the engine at full and varying load, the materials
used for manufacturing of exhaust valve and seat insert, the type and grade of
lubrication oil used, the type and composition of fuel used by the engine, valve
open/closing speed and impact force, straightness adjustment defect, valve rotation
and its angle, etc. [6-19].
The following facts were found by studying the literature review on the discussed test
The microstructure analysis of the exhaust valves will consist of micro-level study of
three categories of Specimens consisting of samples prepared from failed engine
exhaust valves which will be contrasted with the microstructure of new exhaust
valves, in addition the soot deposits on the exhaust valve face are also going to be
studied.
In the analysis process, sample preparation is the essential primary stage, so
Specimens will be taken from the plates of the failed valves and a new valve, and are
going to be prepared by specific standard methods for each of the macro and micro
level examination and metallurgical tests. In addition, a powdered sample is also
going to be acquired from the exhaust valve deposits for the analysis.
Firstly, the samples are going to be viewed using a light microscopy, then the
chemical composition of the plate material and the deposits will be determined by
spectroscopy chemical analysis.
Then the microstructure of the specimen, surface topography (fracture
surface), composition and other properties such as electrical conductivity are going to
be studied by scanning electron microscopy. In addition, the structure, phases and
crystallographic characteristics of valve deposits are going to be identified by X-ray
diffraction (XRD)
Thermo gravimetric analysis (TGA) is also going to be done for a failed
exhaust valve specimen and exhaust valve deposits, which is an analytical technique
used to determine a material’s thermal stability and its fraction of volatile components
by monitoring the weight change that occurs as the specimen is heated.
Figure showing two failed exhaust valve specimens acquired from natural gas powered
engine (Model: G3406)
Sample Light
SEM XRD / XRF TGA Conclusion
preparation microscopy
Work schedule/plan:
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