Powertrain

Linguistics

Engineering

Philosophy

Strain gauge

Aerospace engineering

Residual stress

Materials science

Stress (linguistics)

Automotive industry

Distortion (music)

Component (thermodynamics)

Amplifier

Computer science

Mechanical engineering

Thermodynamics

Physics

Finite element method

Torque

Optics

Automotive engineering

Neutron diffraction

Composite material

Structural engineering

Diffraction

CMOS

Optoelectronics

Materials Science Forum

Residual stress is one of the main reasons for failure of automotive cylinder blocks and engine heads. These failures are typically associated with in-service distortion or cracking occurring in engines during operation cycles. The problem becomes more pronounced for engines that are running at elevated operating pressures and temperatures, limiting R&amp;D options in developing and implementing higher-efficiency engines. New aluminum alloys and manufacturing methods have been introduced with varying degree of success, in many cases affected by the stress magnitudes and stress distribution in the component. Therefore, active research is ongoing internationally on finding the most reliable methods of stress analysis as a basis for developing efficient methods for stress mitigation. The current study presents a comparison between two experimental strain measurements techniques: a destructive method that is based on application of strain gauge sensors, and a non-destructive method using neutron diffraction. The results indicate that although the strain gauge method provides an indication of the nature (i.e. compression or tension) of strain within a component, this method should primarily be used for surface measurements and qualitative analyses only. Neutron diffraction remains the superior technique for strain analysis, particularly for engineering components with complex geometries. The results from this study provide the transportation industry with a more comprehensive understanding of the efficacy of utilizing strain gauge sensors, neutron diffraction or finite element modelling for measuring the residual strain in cast components. The results will help manufacturers to develop the next generation of powertrain systems with increased efficiency and improved performance.

Residual Stress in Automotive Powertrains: Methods and Analyses