Investigation and failure analysis of a diesel generator connecting rod

Abstract

This article reports a failure analysis of a diesel generator set connecting rod type 3516 B that has operated for 79,678 hours. From visual observation, connecting rod cylinder #10 has changed color in the shank area. This phenomenon may represent many cases of generator failure, so an analysis to identify the root cause of the failure is needed for scientific literature. In this case, fault tree analysis, SEM-EDX, chemical composition, and microstructure testing were performed to obtain more comprehensive results. Through fault tree analysis, we found that the connecting rod damage was caused by compression leakage due to wear on the cylinder liner. Scanning Electron Microscopy (SEM) analysis shows that the piston rod material is discolored due to heat, namely the formation of iron oxide. The heat level received by the connecting rod is around 200 °C. We also found a finely formed, easy-to-clean scale where the thickness ranged from 0.00127–0.008 mm. Finally, EDX analysis showed high levels of iron (Fe) and oxygen (O) confirming that the formation of iron-oxide on the metal surface was due to the influence of heat.

Effect on Fatigue Behavior of Connecting Rod in Gasoline Engine

“…In case of fracture, dimples appear on the 45-degree shear lip. The ductile fracture form, resulting from the shear behavior, is elongated or C-shaped, and this parabolic shape may be characteristic of shear failure [11,14]. Figure 7(c) depicts a surface layer examination of the same area.…”

“…SEM analysis revealed that the piston core material was discolored due to heat, namely the formation of iron oxide. The level of heat experienced by the connecting rod was approximately 200 °C and EDX analysis suggested high levels of iron (Fe) and oxygen (O), confirming that the formation of iron oxide on the metal surface is caused by the influence of heat [11]. In [12], the authors adjusted the connecting rod structure.…”

“…The probable root case of damage and some final remarks are presented. Authors in [11] determined that the damage on the connecting rod was caused by a compression leak due to cylinder wear. SEM analysis revealed that the piston core material was discolored due to heat, namely the formation of iron oxide.…”

The Impact of Varying Mixing Rates in a Surfactant-Free Fuel Emulsion Mixer on the Efficiency and Emissions of a Diesel Engine

“…Diesel engines have assumed a pivotal role across diverse sectors, including industrial, transportation, agriculture, marine, and heavy equipment domains. Renowned for their high power output, commendable fuel efficiency, and robust durability, diesel engines have become indispensable for various heavy-duty applications [13]. However, the indispensable nature of diesel engines has spurred concerted efforts to mitigate reliance on conventional diesel fuel.…”