Analysis of a diesel engine cylinder head failure caused by casting porosity defects

• The root cause of the aluminum alloy cylinder head failure is analyzed. • The large size and elongated shape of surface porosity defects play a decisive role in crack initiation. • The multiple cracks initiated from the porosity defect promote the failure of the cylinder head. • Crack causing porosity defects are formed during the casting process. The diesel engine failed in the bench test due to the cracking of its cylinder head, which is...