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There are two important omissions in the literature on bore polishing, firstly there is no evidence of the successful development of a reliable tribo test device to simulate bore polishing and secondly, the mechanism of bore polishing has not been fully defined. The aims of this study were: 1. To establish the principal characteristics of bore polishing In engines. 2. To produce bore polishing in the laboratory. 3. Differentiate between two reference oils in a laboratory tribo test. 4. To understand the mechanism of bore polishing. The principal characteristics of bore polishing have been identified by the examination of Tornado cylinder bores from an engine test. The graphite structure is visible on the surface which has a surface finish of less then 0.125 micro-m in C.L.A. value. The components used in these tests were a grey cast iron piston ring running on a grey cast iron cylinder bore typically used in commercial engines. A reciprocating tribo test was used to distinguish between the two reference oils. The result showed higher friction, wear and a smoother surface with the oil causing bore polishing compared to the other oil which did not produce bore polishing. Adding carbon, taken from the wall of a piston used in an engine test, to the lubricant in the laboratory tribo test produced a phenomenon resembling bore polishing. Comparisons have been made between the tribo test results and service engines and a good correlation has been obtained. Several analytical techniques have been used and the knowledge of bore polishing has been advanced. In particular, it is suggested that a combination of two processes, one mechanical and the other chemical, are associated with bore polishing. Four wear mechanisms were identified during this investigation; abrasion, delamination, corrosion and adhesion.

The aim of this thesis is to design Husqvarna FE 501 turbocharged engine piston for Formula Student competition using bioethanol as its fuel. Proposed concept originates in background research on design solutions of modern combustion engine pistons. FEM simulations are used for piston design.

Durant les régimes de fonctionnement transitoires à froid des technologies d’Injection Directe Essence, des films liquides peuvent se former sur les parois du cylindre moteur. L’interaction entre le gradient de fraction de vapeur, résultant de l’évaporation de ces films avec le front de flamme, est responsable de la majorité des émissions d’hydrocarbures imbrulés (HC). Dans ces travaux, une configuration expérimentale simplifiée a été développée de façon à générer un gradient de fraction de vapeur par évaporation, dans un contexte d’écoulement réactif confiné, mais préservé des complexités inhérentes aux configurations industrielles. L’étude porte sur les influences de la vitesse de l’écoulement et de la température de l’interface de changement de phase sur les intensités des transferts de masse et de chaleur ainsi que sur l’établissement de la stratification de vapeur. Dans un premier temps, les flux de vapeur et de chaleur provenant d’une paroi poreuse saturée en liquide volatil ont été mesurés et évalués. Dans un second temps, le gradient de fraction de vapeur à proximité de la paroi poreuse a été caractérisé par un diagnostic de Fluorescence Induite par Laser (FIL). L’approche globale a confirmé que le flux de chaleur consommé par le changement de phase représente une part importante du flux de chaleur total échangé. De plus, les résultats de mesures de FIL ont montré l’existence de différents types de distributions et comportements provenant du lien étroit entre la forte densité du mélange gazeux et la formation de la couche de vapeur. / During cold start and warm up engine regimes for Gasoline Direct Injection (GDI) technology, fuel liquid films may accumulate on the cylinder walls. The interaction between the mass fraction gradient, witch is resulting from its evaporation, and the front flame, manages to produce the majority of Unburnt HydroCarbon (UHC) emissions. In order to reproduce the conditions found in internal combustion without the industrial setup complexity, an academic experimental configuration has been developed to generate a mass fraction gradient by evaporation. This study focuses on the influence of the air stream velocity and the influence of the phase change interface temperature. First, mass and heat fluxes from the phase change surface have been measured and calculated near a porous wall saturated with volatile liquid. Then, the mass fraction gradient near the porous wall has been characterised by a Laser Induced Fluorescence (LIF) diagnostic. The global approach has confirmed that latent heat flux represents a major part of the total heat transfer flux exchange. Moreover, LIF results have shown different global behaviours that link the high density of the gas mixture to the vapour layer formation.

O presente estudo descreve as alterações metalúrgicas e topográficas do cilindro de blocos de motor de combustão interna fabricados em ferro fundido cinzento, após a realização de testes de durabilidade em dinamômetro. O motor testado tem tecnologia Flex-Fuel, e pode ser operado com qualquer proporção de mistura gasolina comum/etanol. Um motor foi testado com combustível etanol e o outro com gasolina comum, buscando-se assim representar duas condições extremas de trabalho em termos de combustível. A pesquisa constituiu-se da revisão bibliográfica e da parte prática que envolveu: a realização de testes de durabilidade de motor em dinamômetro; a caracterização metalúrgica e topográfica do cilindro após teste com ambos os combustíveis, utilizando técnicas de microscopia eletrônica de varredura, metalografia por microscopia óptica, perfilometria e quantificação de parâmetros de rugosidade, entre outros; a análise crítica, discussão dos resultados e apresentação da conclusão. / The present study approaches the metallurgical and topographical alterations on the cylinder of an internal combustion engine block made of gray cast iron, after durability dynamometer tests. The tested engine has flexible fuel technology (Flex-Fuel), and is capable to work with both gasoline/ethanol fuels, in any mixture proportion. One engine has been tested with ethanol and another one tested with gasoline, and so representing two extreme conditions on which the engine may work in terms of fuel. The research has been developed basically through the conceptual approach by the bibliographic review and the experimental steps that involved: general engine durability test at dynamometer bench; metallurgical and topographic characterization analysis at laboratory, after the test with both fuels, applying Scanning Electronic Microscopy SEM, optical microscopy metallography, profilometer and roughness parameters quantification, and so forth; critical analysis on the results, discussion and final conclusion.

O presente estudo descreve as alterações metalúrgicas e topográficas do cilindro de blocos de motor de combustão interna fabricados em ferro fundido cinzento, após a realização de testes de durabilidade em dinamômetro. O motor testado tem tecnologia Flex-Fuel, e pode ser operado com qualquer proporção de mistura gasolina comum/etanol. Um motor foi testado com combustível etanol e o outro com gasolina comum, buscando-se assim representar duas condições extremas de trabalho em termos de combustível. A pesquisa constituiu-se da revisão bibliográfica e da parte prática que envolveu: a realização de testes de durabilidade de motor em dinamômetro; a caracterização metalúrgica e topográfica do cilindro após teste com ambos os combustíveis, utilizando técnicas de microscopia eletrônica de varredura, metalografia por microscopia óptica, perfilometria e quantificação de parâmetros de rugosidade, entre outros; a análise crítica, discussão dos resultados e apresentação da conclusão. / The present study approaches the metallurgical and topographical alterations on the cylinder of an internal combustion engine block made of gray cast iron, after durability dynamometer tests. The tested engine has flexible fuel technology (Flex-Fuel), and is capable to work with both gasoline/ethanol fuels, in any mixture proportion. One engine has been tested with ethanol and another one tested with gasoline, and so representing two extreme conditions on which the engine may work in terms of fuel. The research has been developed basically through the conceptual approach by the bibliographic review and the experimental steps that involved: general engine durability test at dynamometer bench; metallurgical and topographic characterization analysis at laboratory, after the test with both fuels, applying Scanning Electronic Microscopy SEM, optical microscopy metallography, profilometer and roughness parameters quantification, and so forth; critical analysis on the results, discussion and final conclusion.