A cylinder liner is a cylindrical component that goes inside an engine block to form a cylinder. It is one of the most significant functional components of an engine's interior.
Cylinder Liners, also known as engine sleeves, rebore sleeves, wet liners, dry liners, or simply "liners". And are the replaceable worn parts that can be replaced during an engine overhaul service, avoiding the considerably more expensive replacement of the engine block.
Many cylinder liner manufacturers in India say Cylinder Liners are essential for lowering an engine's total cost of ownership by reducing overhaul time and servicing expenses.
Let's have a look at the following causes of Cylinder Liner Failure
- Due to Friction
When two surfaces move over each other, friction is created, which causes both surfaces to wear down. For example, the surfaces in liner wear are piston rings sliding across the cylinder liner.
Frictional wear is affected by several elements, including the rate of movement between the surfaces, the material used, the temperature, the load on the engine, pressure, maintenance, lubrication, and combustion efficiency.
- Due to Corrosion
Corrosion of the cylinder liner is caused by burning heavy fuel oil in the combustion area and the lower combustion chamber temperature due to the lowered service load.
The burning of heavy fuel oil in the combustion space happens because The sulphur concentration in rich fuel oil is high. Acids are generated inside the area during combustion, which the alkaline nature of cylinder oil should neutralize. If the sulphur level is higher, more acids will be produced, leading to the formation of sulphuric acid.
Maintenance and Assembly ErrorsThe absorption of condensate or moisture present inside the combustion area produces sulphuric acid. While the lower combustions happen because the temperature of the jacket water is so low, sulphuric acid corrosion is more common in the bottom part of the liner. Due to water in the fuel and condensation in the air, sulphur corrosion will be severe.
This wear is most noticeable between the quills. The wear around the quills enlarges, and the wear pattern takes on the appearance of a cloverleaf. As if the cylinder oil quantity is not correctly suited to the load, corrosion of the liner might occur.
- Abrasion
The hard particles present and generated during combustion cause cylinder liner wear. In addition, catalytic fines in the fuel cause abrasive wear, ash created after combustion, metal swarf, dust, and accumulated wear particles in the lubricating oil.
The liner's TDC (Top Dead Centre) and BDC (Bottom Dead Centre) has a higher abrasion wear rate. TDC refers to the position of an internal combustion engine's piston at the top of its stroke, whereas BDC refers to the position of the piston at the bottom of its stroke.
When abrasive wear reaches the metal's surface, it is highly susceptible to corrosion wear due to its exposure to the elements without protection.
- Scuffing or Adhesion
The local welding occurs between the piston ring particles and the liner surface. The welding that has occurred breaks as the piston moves inside the liner, resulting in the creation of abrasive material. The abrasive substance will accelerate the liner's wear rate.
This is usually caused by a lack of lubrication, which results in a considerable amount of heat being produced and microscopic welding of the rings and liner surface. In addition, the liner loses its ability to bind cylinder oil to the surface due to this form of wear. Another cause of this phenomenon is scuffing, which polishes the surface and gives liners a mirror shine.
- Twisted Liner O-Ring
O-rings wear out or break over time and must be replaced. O-rings can break down for various causes like excessive combustion; Rapid pressure changes develop blisters, pocks, or pits on its surface. In addition, you can find Small cuts, nicks, and gashes on the O-Ring due to installation issues.
The O-Ring, or parts of it, have a flat surface that is parallel to the motion. Due to friction from a rough sealing surface, loose particles and scrapes may be observed on the sealing surface. Due to high clearances, the O-Ring acquires ragged edges that resemble tattered. Additionally, some elastomers may show signs of softening. This is related to severe heat exposure.
Due to chemical incompatibility, the O-Ring may show signs of degradation such as blisters, cracks, voids, or discolouration.
- Maintenance and Assembly Errors
Every cylinder liner requires adequate maintenance and needs to determine the assembly errors to know what grade of cylinder oil to use and maintain proper jacket water temperature and the fuel injector and fuel system for adequate atomization and injection of fuel inside the chamber.
In addition, correctly handling the fuel oil and moisture from the charged air can avoid any water entry into the liner.
Garima Global under the AutoGRACE® brand offers a diverse selection of cylinder liner manufacturers. Divided into three categories: monolithic, inserted, and bonded, insert technology liners are by far the most popular due to their simplicity of maintenance and lower reconditioning costs.
Our cylinder liners are designed to wear controlled to protect more expensive parts such as pistons and engine blocks from wear. In addition, they provide a surface against which piston rings can slide with the least friction and maximum sealing, preventing combustion gases from escaping into the crankcase or lubricating oil from entering the combustion chamber. And Conducts heat combustion away from the combustion chamber and into the coolant.
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