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This work investigates the causes of wear occurring at the engine valve tip end after 400 hours of engine operation. Fatigue wear was observed on the valve tip at the product development stage of the engine, which is going to be used in an automotive vehicle. Valves were assembled on a gasoline/CNG fuel-based four-cylinder IC engine. In this engine, tip end wear was prominent during high-speed testing conditions as compared to other types of engine tests. The chemical composition of worn surfaces was verified by spectroscopy. The microstructures, grain sizes and surface roughness were determined by optical microscopy and surface roughness tester. To evaluate the wear mechanism, valve tip end worn surfaces were analyzed using Scanning electron microscopy. The SEM analysis indicates the initiation of micropits and subsequent propagation of the fatigue wear during engine operating conditions. The residual stresses were measured at valve tip end surfaces and subsurfaces using X-ray diffraction techniques. Several investigations employing multiple techniques were carried out to identify the root cause of failure while comparing results against those of untested valves. Parameters that can affect valve tip end properties were identified in the study and countermeasures provided, and that lead to successful completion of the testing with the same operating condition.

Investigation of Valve Tip End Wear Mechanism of a Four-Cylinder Automotive Engine Under High-Speed Application