Root Cause Analysis of Water-Cooled Exhaust Manifold in High Speed Marine Diesel Engine

Document Type : Research Paper

Authors

1 Professor of Mechanical Engineering, Shahrood University of Technology, Shahrood, Iran.

2 Master of Materials Engineering, Dina Motors Company, Tehran, Iran.

Abstract

In marine diesel engines with high power to weight ratio, water-cooled exhaust manifolds are designed and manufactured to achieve a good heat transfer in exhaust system with appropriate safety and reliability in engine room. In one of high-speed marine diesel engine after 417 hours operation, water was leaked from aluminum alloy exhaust manifold due to cavity creation between coolant and gas port walls. This paper investigates the root cause analysis of this exhaust manifold failure using fishbone diagram. Results showed that film boiling was accrued on damaged surface. In this region, surface was completely covered by a continuous stable vapor film. So, heat flux of this area reached a minimum and surface temperature was increased locally. The root cause of this phenomena was decreasing or blocking of water flow due to some unwanted casting burr. Although the film boiling nucleated thermal crack on surface, but cracks and cavities propagated under an electro-chemical mechanism until coolant leakage.

Keywords

References

1. Mohrmann, R., Seifert, T., Willeke, W., Hartmann, D., "Fatigue life simulation for optimized exhaust manifold geometry", SAE Technical Papers, 2006. https://doi.org/10.4271/2006-01-1249
2. Zieher, F., Langmayr, F., Ennemoser, A., Jelatancev, A., Hager, G., Wieser, K., "Advanced Thermal Mechanical Fatigue Life Simulation of Cylinder Heads", ABAQUS Users, vol. 1000, pp. 789–805, 2004.
3. Milanovic, R., Zhou, C.Q., Majdak, J., Cantwell, R., "CFD modeling of flow and heat transfer inside a liquid-cooled exhaust manifold", in Proceedings of the ASME Summer Heat Transfer Conference, vol. 2003, pp. 785–792, 2003.  https://doi.org/10.1115/HT2003-47294
4. Korczewski, Z., "Exhaust gas temperature measurements in diagnostics of turbocharged marine internal combustion engines Part II dynamic measurements", Polish Maritime Research, vol. 23, pp. 68–76, 2016. http://dx.doi.org/10.1515/pomr-2016-0010
5. Assari, M.R., Adeli, S., "New Design and Analysis of Diesel Exhaust Manifold to Control Thermal Gradient", vol. 3, pp. 53–62, 2019.
6. Hamitt, F.g., "Bubble Dynamics of Cavitation and Boiling", 1997.  https://dx.doi.org/10.22060/ajme.2018.14440.5729
7. Lienhard, IV, J. H. and Lienhard, V, J. H.}, "A Heat Transfer Textbook", Phlogiston Press, 2020, 5th edition, http://ahtt.mit.edu.
8.Mehdipour R, Nazaktabar M, Baniamerian Z, Aghanajafi C. Simulation of Heat Transfer in the Cooling Passages of the “EF7” Engine Considering Boiling Phenomenon. JER. 2010; 19 (19) :64-73
URL: http://engineresearch.ir/article-1-218-fa.html
9. Kaufman, J.G., Rooy, E.L., "Aluminum Alloy Casting Properties Processes and Applications", ASM International, 2004. ISBN: 978-0-87170-803-8.
10. Sarkar, A.D., "Wear of Aluminum-Silicon Alloys", Wear, vol. 2, pp. 331-334, 1975. https://doi.org/10.1016/0043-1648(75)90167-2
11. Sharma, R., Anesh, D., Dwivedi, K., "Influence of Silicon (wt.%) and Heat Treatment on Abrasive Wear Behaviour of Cast Al-Si-Mg alloys", Materials Science and Engineering, vol. 12, pp. 274-280, 2005. https://doi.org/10.1016/j.msea.2005.08.013
12. حامد فتاحی، مهدی جلالی عزیزپور، " بررسی تجربی و عددی تنش پسماند در فرایند شکل دهی ورق داغ آلومینیوم 5083 با دمش گاز"، مجله مواد نوین، جلد7، شماره 1، ص 22-13، پاییز 1395.
13. Davis, J.R., Corrosion of Aluminum and Aluminum Alloys", ASM International, 1999. https://doi.org/10.31399/asm.tb.caaa.9781627082990
14. Videm, K., "Corrosion of Aluminum Alloys in High Temperature Water - A Survey", Journal of Nuclear Materials, vol. 2, pp. 145-153, 1959. https://doi.org/10.1016/0022-3115(59)90048-0

Files

History

  • Receive Date: 06 March 2020
  • Revise Date: 06 May 2021
  • Accept Date: 12 May 2021

Share

How to cite

Statistics