Premature Engine Failure Due to Improper Surface Finish Caused by Carbon Flotation
Nodular cast iron crankshafts and their main-bearing inserts were causing premature failures in engines within the first 1600 km (1000 mi) of operation. The failures were indicated by internal noise, operation at low pressure, and total seizing. Concurrent with the incidence of engine field failures was a manufacturing problem: the inability to maintain a similar microfinish on the cope and drag sides of a cast main-bearing journal. Investigation supported the conclusion that the root cause of the failure was carbon flotation due to the crankshafts involved in the failures showing a higher-than-normal carbon content and/or carbon equivalent. Larger and...
Premature Engine Failure Due to Improper Surface Finish Caused by Carbon Flotation, ASM Failure Analysis Case Histories: Processing Errors and Defects, ASM International, 2019, https://doi.org/10.31399/asm.fach.process.c0089646
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