A indústria automotiva exige produtos que trabalhem em condições extremas. O desenvolvimento de componentes é uma ação de aperfeiçoar os motores de combustão interna para que atinjam a vida requerida com níveis de desgaste aceitáveis, respeitando os limites legais de operação, como por exemplo, valores de emissões de poluentes. Diante dessas exigências, se faz necessário estudar componentes considerados críticos que conhecidamente influenciam no desempenho do motor. A tribologia do par válvula e sede de válvula de admissão é um importante conjunto que se deve ter atenção quanto ao seu desgaste, visto que pode influenciar na degradação do motor quanto aos parâmetros de emissões de poluentes e requisitos operacionais de manutenção e de vida do produto. O objetivo foi avaliar o comportamento do par tribológico, válvula e sede de válvula de admissão, submetidos a ensaios em dinamômetro e veiculares (condições reais de operação), quanto ao nível e tipo de desgaste ocorrido no par. Os resultados obtidos foram correlacionados com os requisitos de desempenho legais e operacionais de um motor ciclo diesel, como também foi realizada a caracterização do tipo de desgaste ocorrido no par tribológico e comparada com a literatura específica. Com base nos resultados, concluiu-se que ocorreu uma excelente compatibilidade entre a válvula e a sede da válvula de admissão; o nível de desgaste não prejudicou o desempenho do motor e as emissões de poluentes; o par tribológico atendeu aos requisitos de trabalho extremos, como operação em altas temperaturas e pressão de combustão com baixas taxas de desgaste; e os tipos de desgastes observados foram classificados como desgaste adesivo e sinais de deformação plástica. / Automotive industry demands products that work under extreme conditions. The development of components for internal combustion engines is an action to improve this product, so that it reaches the required life with acceptable levels of wear and respecting the legal operating limits, such as values of emission pollutants. In view of these requirements, it is necessary to study components considered critical, which are known to influence the performance of the engine. So within this universe the tribology of the intake valve and valve seat insert is an important set, that must receive attention to its wear and consequently its influence to the engine degradation in the parameters of emission pollutants and performance related to the operational maintenance requirements and life of the product. The aim of this work is to evaluate the behavior of the tribological intake pair, valve and valve seat insert, submitted to dynamometer and vehicular tests (real operating conditions), regarding the level and type of wear occurred in the pair. The results were compared with legal and operational performance requirements of a diesel cycle engine, as well as the characterization of the wear type occurred in the tribological pair, with the related literature. Based on the results it was concluded that there was excellent compatibility between the valve and the valve seat material; the wear level did not impar the engine performance and emissions of pollutants; the tribological pair meeting extreme work requirements, such as high temperature operation and combustion pressure while maintaining low wear rates. The wear types observed were classified as adhesive wear and slight signs of shear strain wear.

A indústria automotiva exige produtos que trabalhem em condições extremas. O desenvolvimento de componentes é uma ação de aperfeiçoar os motores de combustão interna para que atinjam a vida requerida com níveis de desgaste aceitáveis, respeitando os limites legais de operação, como por exemplo, valores de emissões de poluentes. Diante dessas exigências, se faz necessário estudar componentes considerados críticos que conhecidamente influenciam no desempenho do motor. A tribologia do par válvula e sede de válvula de admissão é um importante conjunto que se deve ter atenção quanto ao seu desgaste, visto que pode influenciar na degradação do motor quanto aos parâmetros de emissões de poluentes e requisitos operacionais de manutenção e de vida do produto. O objetivo foi avaliar o comportamento do par tribológico, válvula e sede de válvula de admissão, submetidos a ensaios em dinamômetro e veiculares (condições reais de operação), quanto ao nível e tipo de desgaste ocorrido no par. Os resultados obtidos foram correlacionados com os requisitos de desempenho legais e operacionais de um motor ciclo diesel, como também foi realizada a caracterização do tipo de desgaste ocorrido no par tribológico e comparada com a literatura específica. Com base nos resultados, concluiu-se que ocorreu uma excelente compatibilidade entre a válvula e a sede da válvula de admissão; o nível de desgaste não prejudicou o desempenho do motor e as emissões de poluentes; o par tribológico atendeu aos requisitos de trabalho extremos, como operação em altas temperaturas e pressão de combustão com baixas taxas de desgaste; e os tipos de desgastes observados foram classificados como desgaste adesivo e sinais de deformação plástica. / Automotive industry demands products that work under extreme conditions. The development of components for internal combustion engines is an action to improve this product, so that it reaches the required life with acceptable levels of wear and respecting the legal operating limits, such as values of emission pollutants. In view of these requirements, it is necessary to study components considered critical, which are known to influence the performance of the engine. So within this universe the tribology of the intake valve and valve seat insert is an important set, that must receive attention to its wear and consequently its influence to the engine degradation in the parameters of emission pollutants and performance related to the operational maintenance requirements and life of the product. The aim of this work is to evaluate the behavior of the tribological intake pair, valve and valve seat insert, submitted to dynamometer and vehicular tests (real operating conditions), regarding the level and type of wear occurred in the pair. The results were compared with legal and operational performance requirements of a diesel cycle engine, as well as the characterization of the wear type occurred in the tribological pair, with the related literature. Based on the results it was concluded that there was excellent compatibility between the valve and the valve seat material; the wear level did not impar the engine performance and emissions of pollutants; the tribological pair meeting extreme work requirements, such as high temperature operation and combustion pressure while maintaining low wear rates. The wear types observed were classified as adhesive wear and slight signs of shear strain wear.

Desde a sua invenção, o motor a combustão interna sofreu significantes evoluções, como redução do consumo de combustível, aumento da sua potência e durabilidade a um menor custo. Outros setores também evoluíram, como a busca por alternativas de combustível, tendo como exemplo o etanol hidratado combustível, que trouxe vantagens tais como maior desempenho e menor emissão de poluentes, porém com solicitações mecânicas, térmicas e termomecânicas mais severas. Sua menor lubricidade, quando comparada a da gasolina tipo C também intensificou o desgaste no par tribológico válvula e sede de válvula. Neste trabalho foram analisados diversos pares de válvulas e sedes de válvulas provenientes de quatro motores pós teste, sendo dois deles de mesma especificação técnica e submetidos às mesmas condições de ensaio, variando somente o combustível utilizado (etanol hidratado combustível e gasolina comum tipo C). A topografia da superfície de contato foi avaliada através de exames das superfícies com lupa estereoscópica, microscópio eletrônico de varredura e perfilômetro óptico a fim de identificar os danos encontrados. Ao término das análises foi realizada a comparação dos danos encontrados entre a superfície de contato das válvulas e sedes do motor que operou com etanol hidratado combustível e gasolina comum tipo C, de forma a evidenciar as diferenças proporcionadas pelos combustíveis. Este trabalho faz parte do \"Consórcio de P&D e Desafios Tribológicos em Motores Flex-Fuel\" patrocinado pela FAPESP (Fundação de Amparo à Pesquisa do Estado de São Paulo) com participação da indústria automotiva, para identificar os modos de desgaste atuantes. / Since its invention the internal combustion engine presented significant improvements like lower fuel consumption, higher power and durability increase at reduced costs. Other industries sectors did also improve as the search for new alternative fuels such as hydrated ethanol fuel which brought advantages like higher performance with lower pollutant emissions, although with it came more severe mechanical, thermal and thermo-mechanic stresses. Ethanol lower lubricity when compared to type C gasolines did also increase the valve/ valve seat insert wear. This study presents the results of contact surface analysis of several pairs valve/ valve seat insert from four engines after test being two of them of same technical specification and submitted to the same test cycle with only difference their fuel (hydrated ethanol and regular type C gasoline). The contact surface topography was evaluated through surface exams using optical microscopy, scanning electron microscope and non-contact profiler, to evaluate damages. At the end of analysis, a comparison between valves and valve seats from the engines that operated with hydrated ethanol and regular type C gasoline in order to put in evidence the damage difference provided by the fuels. This study is part of \"Consórcio de P&D e Desafios Tribológicos em Motores Flex-Fuel\", sponsored by FAPESP (\"Fundação de Amparo à Pesquisa do Estado de São Paulo\") with participation of automotive industries, to characterize the existent wear.

Desde a sua invenção, o motor a combustão interna sofreu significantes evoluções, como redução do consumo de combustível, aumento da sua potência e durabilidade a um menor custo. Outros setores também evoluíram, como a busca por alternativas de combustível, tendo como exemplo o etanol hidratado combustível, que trouxe vantagens tais como maior desempenho e menor emissão de poluentes, porém com solicitações mecânicas, térmicas e termomecânicas mais severas. Sua menor lubricidade, quando comparada a da gasolina tipo C também intensificou o desgaste no par tribológico válvula e sede de válvula. Neste trabalho foram analisados diversos pares de válvulas e sedes de válvulas provenientes de quatro motores pós teste, sendo dois deles de mesma especificação técnica e submetidos às mesmas condições de ensaio, variando somente o combustível utilizado (etanol hidratado combustível e gasolina comum tipo C). A topografia da superfície de contato foi avaliada através de exames das superfícies com lupa estereoscópica, microscópio eletrônico de varredura e perfilômetro óptico a fim de identificar os danos encontrados. Ao término das análises foi realizada a comparação dos danos encontrados entre a superfície de contato das válvulas e sedes do motor que operou com etanol hidratado combustível e gasolina comum tipo C, de forma a evidenciar as diferenças proporcionadas pelos combustíveis. Este trabalho faz parte do \"Consórcio de P&D e Desafios Tribológicos em Motores Flex-Fuel\" patrocinado pela FAPESP (Fundação de Amparo à Pesquisa do Estado de São Paulo) com participação da indústria automotiva, para identificar os modos de desgaste atuantes. / Since its invention the internal combustion engine presented significant improvements like lower fuel consumption, higher power and durability increase at reduced costs. Other industries sectors did also improve as the search for new alternative fuels such as hydrated ethanol fuel which brought advantages like higher performance with lower pollutant emissions, although with it came more severe mechanical, thermal and thermo-mechanic stresses. Ethanol lower lubricity when compared to type C gasolines did also increase the valve/ valve seat insert wear. This study presents the results of contact surface analysis of several pairs valve/ valve seat insert from four engines after test being two of them of same technical specification and submitted to the same test cycle with only difference their fuel (hydrated ethanol and regular type C gasoline). The contact surface topography was evaluated through surface exams using optical microscopy, scanning electron microscope and non-contact profiler, to evaluate damages. At the end of analysis, a comparison between valves and valve seats from the engines that operated with hydrated ethanol and regular type C gasoline in order to put in evidence the damage difference provided by the fuels. This study is part of \"Consórcio de P&D e Desafios Tribológicos em Motores Flex-Fuel\", sponsored by FAPESP (\"Fundação de Amparo à Pesquisa do Estado de São Paulo\") with participation of automotive industries, to characterize the existent wear.

Controlling the temperature of the exhaust valves is paramount for proper functioning of engines and for the long lifespan of valve train components. The majority of the heat outflow from the valve takes place along the valve-seat-cylinder head-coolant thermal path which is significantly influenced by the thermal contact resistance (TCR) present at the valve/seat and seat/head interfaces. A test rig facility and experimental procedure were successfully developed to assess the effect of the valve/seat and seat/head interfaces on heat outflow from the valve, in particular the effects of the valve/seat interface geometry, seat insert assembly method, i.e. press or shrink fit, and seat insert metallic coating on the operating temperature of the valve. The results of tests have shown that the degree of the valve-seat geometric conformity is more significant than the thermal conductivity of the insert: for low conforming assemblies, the mean valve head temperature recorded during tests on copper-infiltrated insert seats was higher than that recorded during tests on noninfiltrated seats of higher conformance. The effect of the insert-cylinder head assembly method, i.e. shrink-fitted versus press-fitted inserts, has proved negligible: results have shown insignificant valve head temperature variations, for both tin-coated and uncoated inserts. On the other hand, coating the seat inserts with a layer of tin (20-22μm) reduced the mean valve head temperature by approximately 15°C as measured during tests on uncoated seats. The analysis of the valve/seat and seat/head interfaces has indicated that the surface asperities of the softer metal in contact would undergo plastic deformation. Suitable thermal contact conductance (TCC) models, available in the public domain, were used to evaluate the conductance for the valve/seat and seat/cylinder head interfaces. Finally, a FE thermal model of the test rig has been developed with a view to assess the quality of the calculated TCC values for the valve/seat and seat/head interfaces. The results of the thermal analysis have shown that predicted temperatures at chosen control points agree with those measured during tests on thermometric seats with an acceptable level of accuracy, proving the effectiveness of the used TCC models.

Atualmente, uns dos grandes desafios para a indústria automobilística é aumentar o desempenho do conjunto mecânico responsável por selar a câmara de combustão interna de motores automotivos e também reduzir os seus custos de obtenção. O objetivo deste trabalho foi o de tratar termicamente insertos de assentos de válvulas (do inglês valve seat insert, VSI) obtidos pela rota de metalurgia do pó. Esta técnica possibilitou a substituição do cobalto e do chumbo, devido ao seu elevado custo e efeito toxicológico, respectivamente. Ao longo do trabalho foram avaliados VSI obtidos com três misturas de pós diferentes, sendo que os elementos comuns nestas três misturas foram os pós de ferro, sulfeto de manganês, carboneto de nióbio, grafite, estearato de zinco e cobre. Em cada uma destas misturas variou-se apenas os tipos de pós de aços rápidos e aço ferramenta utilizado, sendo estes o aço rápido AISI M3:2 (Mistura 1), aço rápido AISI M2 (Mistura 2) e aço ferramenta AISI D2 (Mistura 3). Os tratamentos térmicos aplicados aos VSI consistiram em têmpera ao ar e têmpera ao óleo, ambas seguidas de duplo revenimento em sete temperaturas equidistantemente diferentes, variando de 100 °C a 700 °C. Os ciclos dos tratamentos térmicos foram determinados por meio da utilização de termopares do tipo k acoplados à um sistema de aquisição de dados. As propriedades físicas e mecânicas dos VSI foram determinadas através da dureza aparente, densidade aparente e resistência à ruptura radial. A caracterização microestrutural foi realizada utilizando-se a microscopia óptica e microscopia eletrônica de varredura. A composição química foi determinada por meio da análise elementar e por espectrometria de fluorescência de energia dispersiva de raios X. Os melhores resultados em relação às propriedades mecânicas dos VSI foram obtidas para os insertos temperados ao ar e duplamente revenido a 600 °C para a Mistura 1 e Mistura 2, e a 500 °C para Mistura 3. Já para a têmpera ao óleo, as melhores respostas foram para os VSI obtidos com a Mistura 1 duplamente revenida a 400 °C e a, 300 °C para os componentes obtidos com a Mistura 2 e Mistura 3. / Currently, one of the biggest challenges for the automobile industry is to increase the performance of the mechanical set responsible for sealing the internal combustion chamber in automotive engines and reduce its cost of production. The aim of the present work was to heat treat valve seat inserts (VSI) obtained through the powder metallurgy route. This procedure made possible the substitution of cobalt and lead, due to its high cost and toxicological effect, respectively. Throughout the work, it was evaluated VSI obtained with three different types of powders mixtures, and common elements at the three different powders mixtures were iron powder, manganese sulfide, niobium carbide, graphite, zinc stearate and copper. In each of these powders mixtures, it was changed only the type of high-speed steels and tool steel, consisting of high-speed steel AISI M3:2 (Mixture 1), high-speed steel AISI M2 (Mixture 2) and tool steel AISI D2 (Mixture 3). The heat treatments applied to the VSI were air quenching and oil quenching, both followed by double tempering at seven different equidistantly temperatures, ranging from 100 °C up to 700 °C. The heat treatments thermal cycles were determined using a thermocouple type k attached to a data acquisition system. The physical and mechanical properties of the VSI were measured in terms of apparent hardness, apparent density and crush radial strength. Microstructural characterization was performed using optical and scanning electron microscopy. The chemical composition was determined using gas analysis and energy dispersive X-ray fluorescence spectrometry. The best results regarding the mechanical properties of the VSI were obtained for the VSI air-quenched and double tempered at 600 °C for the powder Mixture 1 and Mixture 2, and at 500 °C for Mixture 3. For the oil quenching, the best response was reached for the VSI obtained with Mixture 1 double tempered at 400 °C, and at 300 °C for the components obtained with Mixture 2 and Mixture 3.

Atualmente, uns dos grandes desafios para a indústria automobilística é aumentar o desempenho do conjunto mecânico responsável por selar a câmara de combustão interna de motores automotivos e também reduzir os seus custos de obtenção. O objetivo deste trabalho foi o de tratar termicamente insertos de assentos de válvulas (do inglês valve seat insert, VSI) obtidos pela rota de metalurgia do pó. Esta técnica possibilitou a substituição do cobalto e do chumbo, devido ao seu elevado custo e efeito toxicológico, respectivamente. Ao longo do trabalho foram avaliados VSI obtidos com três misturas de pós diferentes, sendo que os elementos comuns nestas três misturas foram os pós de ferro, sulfeto de manganês, carboneto de nióbio, grafite, estearato de zinco e cobre. Em cada uma destas misturas variou-se apenas os tipos de pós de aços rápidos e aço ferramenta utilizado, sendo estes o aço rápido AISI M3:2 (Mistura 1), aço rápido AISI M2 (Mistura 2) e aço ferramenta AISI D2 (Mistura 3). Os tratamentos térmicos aplicados aos VSI consistiram em têmpera ao ar e têmpera ao óleo, ambas seguidas de duplo revenimento em sete temperaturas equidistantemente diferentes, variando de 100 °C a 700 °C. Os ciclos dos tratamentos térmicos foram determinados por meio da utilização de termopares do tipo k acoplados à um sistema de aquisição de dados. As propriedades físicas e mecânicas dos VSI foram determinadas através da dureza aparente, densidade aparente e resistência à ruptura radial. A caracterização microestrutural foi realizada utilizando-se a microscopia óptica e microscopia eletrônica de varredura. A composição química foi determinada por meio da análise elementar e por espectrometria de fluorescência de energia dispersiva de raios X. Os melhores resultados em relação às propriedades mecânicas dos VSI foram obtidas para os insertos temperados ao ar e duplamente revenido a 600 °C para a Mistura 1 e Mistura 2, e a 500 °C para Mistura 3. Já para a têmpera ao óleo, as melhores respostas foram para os VSI obtidos com a Mistura 1 duplamente revenida a 400 °C e a, 300 °C para os componentes obtidos com a Mistura 2 e Mistura 3. / Currently, one of the biggest challenges for the automobile industry is to increase the performance of the mechanical set responsible for sealing the internal combustion chamber in automotive engines and reduce its cost of production. The aim of the present work was to heat treat valve seat inserts (VSI) obtained through the powder metallurgy route. This procedure made possible the substitution of cobalt and lead, due to its high cost and toxicological effect, respectively. Throughout the work, it was evaluated VSI obtained with three different types of powders mixtures, and common elements at the three different powders mixtures were iron powder, manganese sulfide, niobium carbide, graphite, zinc stearate and copper. In each of these powders mixtures, it was changed only the type of high-speed steels and tool steel, consisting of high-speed steel AISI M3:2 (Mixture 1), high-speed steel AISI M2 (Mixture 2) and tool steel AISI D2 (Mixture 3). The heat treatments applied to the VSI were air quenching and oil quenching, both followed by double tempering at seven different equidistantly temperatures, ranging from 100 °C up to 700 °C. The heat treatments thermal cycles were determined using a thermocouple type k attached to a data acquisition system. The physical and mechanical properties of the VSI were measured in terms of apparent hardness, apparent density and crush radial strength. Microstructural characterization was performed using optical and scanning electron microscopy. The chemical composition was determined using gas analysis and energy dispersive X-ray fluorescence spectrometry. The best results regarding the mechanical properties of the VSI were obtained for the VSI air-quenched and double tempered at 600 °C for the powder Mixture 1 and Mixture 2, and at 500 °C for Mixture 3. For the oil quenching, the best response was reached for the VSI obtained with Mixture 1 double tempered at 400 °C, and at 300 °C for the components obtained with Mixture 2 and Mixture 3.

This thesis focus with construction design intake manifold of four stroke engine rallyecross division 1A. For improvement observant come into operating here derive benefit from theory tuned supercharging, which is based on tuning longitudes sucking conduit. Derive benefit woolen effect. Driving unit is here used four cylinders, water-cooled, atmospheric combustion engine from car VW Polo 6N GTI. Design is created so, to answer condition division 1A.

Controlling the temperature of the exhaust valves is paramount for proper functioning of engines and for the long lifespan of valve train components. The majority of the heat outflow from the valve takes place along the valve-seat-cylinder head-coolant thermal path which is significantly influenced by the thermal contact resistance (TCR) present at the valve/seat and seat/head interfaces. A test rig facility and experimental procedure were successfully developed to assess the effect of the valve/seat and seat/head interfaces on heat outflow from the valve, in particular the effects of the valve/seat interface geometry, seat insert assembly method, i.e. press or shrink fit, and seat insert metallic coating on the operating temperature of the valve. The results of tests have shown that the degree of the valve-seat geometric conformity is more significant than the thermal conductivity of the insert: for low conforming assemblies, the mean valve head temperature recorded during tests on copper-infiltrated insert seats was higher than that recorded during tests on noninfiltrated seats of higher conformance. The effect of the insert-cylinder head assembly method, i.e. shrink-fitted versus press-fitted inserts, has proved negligible: results have shown insignificant valve head temperature variations, for both tin-coated and uncoated inserts. On the other hand, coating the seat inserts with a layer of tin (20-22¿m) reduced the mean valve head temperature by approximately 15°C as measured during tests on uncoated seats. The analysis of the valve/seat and seat/head interfaces has indicated that the surface asperities of the softer metal in contact would undergo plastic deformation. Suitable thermal contact conductance (TCC) models, available in the public domain, were used to evaluate the conductance for the valve/seat and seat/cylinder head interfaces. Finally, a FE thermal model of the test rig has been developed with a view to assess the quality of the calculated TCC values for the valve/seat and seat/head interfaces. The results of the thermal analysis have shown that predicted temperatures at chosen control points agree with those measured during tests on thermometric seats with an acceptable level of accuracy, proving the effectiveness of the used TCC models.

The urgent need to reduce green house gas emissions from the transport sector, particularly from heavy-duty trucks, has underscored the importance of developing more efficient internal combustion engines. Using computational fluid dynamics (CFD), this work investigated the impact of valve seat geometry on in-cylinder swirl, addressing a gap in research. Additionally, the suitability of steady-state simulations for providing valid qualitative data on port flow was assessed. To answer both research questions, two approaches were followed: steady-state port flow RANS simulations, and transient RANS simulations in a running engine setup. The results from the steady-state simulations highlighted the limitations of this approach to qualitatively predict swirl, as this quantity is highly dependent on the mesh. Despite these limitations, the steady-state simulations were still able to capture the trade-off between swirl and discharge coefficient, outlined in the literature. Transient simulations revealed that in-cylinder swirl is affected by the geometry of the valve seats. It was found that valve seats that direct the flow towards the liner, while avoiding strong flow separation tend to promote higher swirl, whereas valve seats that induce strong flow separation lead to lower swirl ratios. Despite the trade-off between swirl and volumetric efficiency, the volumetric efficiency losses were found to be practically negligible. The study emphasizes the need for a more comprehensive set of simulations, including more valve lifts and pressure ratios. Given the unsuitability of the steady-state simulations to predict swirl trends, future investigations should focus on replacing this approach by transient simulations with steady-state geometry and boundary conditions, properly addressing flow time-dependency at relatively low computational cost, and facilitating validation with experimental data.