Connecting Rod Fault

Lion DVD
AFA I
CHAPTER: Connecting Rods
Connecting Rods
Service Training Malaga
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AFA I
Nomenclature
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Loads
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Compressive and Tensile
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Loads
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Bending
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High Stress Areas
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Manufacturing
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Grain flow
Forged Steel
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AFA I
Manufacturing
Heat treated to Rc 32
Shot peened
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Manufacturing
AFA I
Rod Eye
Bushing pressed
and Broached
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Manufacturing
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Big End
Matching
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Normal Appearance
Tin Flash
10
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Normal Appearance
11
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Normal Appearance
Cross hatch Pattern
12
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Abnormal Conditions
External Forces
Bearing Failures
Rebuild Errors
Loose or Broken Bolts
13
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Rod
Rod is Bent
14
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Rod
AFA I
No marks on the top of the piston
15
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Rod bearing
16
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Rod
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Hydraulic Lock
17
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AFA I
Abnormal Conditions
External Forces
Bearing Failures
Rebuild Errors
18
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Case 1.
AFA I
What do you see ?
19
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Piston
Rough surface, no plastic deformation
Brittle fracture due to

sudden impact load
E
R
T
L
U
S
20
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AFA I
Big End
Heat discoloration
Can indicate bearing failure
21
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Big End
AFA I
Heat discoloration, Thermal cracks
Bearing have spun
22
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Cap
AFA I
Fretting Corrosion
Joint have been lose

or overloaded
23
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AFA I
Shank
Beach Marks
Fatigue Fracture
Beach marks
Normal stress raiser
24
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AFA I
What is the cause of the failure ?

Bearing failed causing vibration
overloading the shank
25
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Case 2.
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What do you see ?
26
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Big End
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Discoloration
Failed Bearing ?
27
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Big End
Fretting Corrosion, Ductile Fracture
Joint movement
E
R
T
L
U
S
28
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Cap
AFA I
Polishing around nut seating face
29
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Bolt & Nut
AFA I
Damaged Treads
30
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Bolt & Nut
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Damaged Treads
31
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Nut
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Deformed
32
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What is the cause of the failure ?
33
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AFA I
Abnormal Conditions
External Forces
Bearing Failures
Rebuild Errors
34
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Case 3.
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What do you see ?
35
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Rod
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Hinged, No Cross Hatch Pattern
36
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Bearing
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Undersized
37
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Rod
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Fatigue Fracture
38
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Abnormal Conditions
External Forces
Bearing Failures
Rebuild Errors
39
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Case 4.
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What do you see ?
40
Lion DVD
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Rod
Hinged open, Ductile Fracture
Do not blame me !
E
R
T
L
U
S
41
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Rod
AFA I
Polishing, No Fretting
42
Lion DVD
AFA I
Rod
Smoot, silky appearance
Ductile impact shear
E
R
T
L
U
S
43
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Bolt & Nut
AFA I
Damaged and stripped threads
Lose Nut
44
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Case 5.
AFA I
What do you see ?
45
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Bearing
AFA I
Undersized
, Secondary damage No Failure
Someone have been

working on the engine
46
Lion DVD
AFA I
Rod
Hinged, Ductile fracture
Look at the other side !
E
R
T
L
U
S
47
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AFA I
Rod Fracture
Smooth silky surface
Impact Shear
E
R
T
L
U
S
48
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Bolt
AFA I
Beach marks
No high stress area
49
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Bolt
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Dent in the knurled area
50
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Connecting Rod Problems
Forging Laps
Heat Treat
Machining/ Shot Peening
Assembly
51
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Forging Lap
52
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Case 6.
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What do you see ?
53
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Bearing
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Damaged but not failed
54
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Cap
Dark, Rough with deformation
E
R
T
L
U
S
55
Lion DVD
Rod
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Beach marks, Ratchet marks
Subsurface
56
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Rod
AFA I
Beach marks, Ratchet marks
Forging Lap
57
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AFA I
Forging Laps
Heat Treat
Assembly
58
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Quench Crack
59
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Quench Crack
60
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Forging Laps
Heat Treat
Assembly
61
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Case 7.
AFA I
What do you see ?
62
Lion DVD
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Rod
Hinged, Ductile Fracture
I have told you before

dont look at me !
E
R
T
L
U
S
63
Lion DVD
Cap
AFA I
Beachmarks
64
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Cap
AFA I
Where is the initiation site ?
65
Lion DVD
AFA I
Cap
Bad shot peening
66

Connecting Rod Fault

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Connecting Rod Fault

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Lion DVD

CHAPTER: Connecting Rods

CHAPTER: Connecting Rods

Service Training Malaga

Service Training Malaga

CHAPTER: Connecting Rods

Compressive and Tensile

Service Training Malaga

CHAPTER: Connecting Rods

CHAPTER: Connecting Rods

High Stress Areas

Service Training Malaga

CHAPTER: Connecting Rods

Service Training Malaga

CHAPTER: Connecting Rods

Service Training Malaga

CHAPTER: Connecting Rods

Service Training Malaga

CHAPTER: Connecting Rods

Service Training Malaga

Service Training Malaga

CHAPTER: Connecting Rods

CHAPTER: Connecting Rods

Service Training Malaga

CHAPTER: Connecting Rods

Service Training Malaga

CHAPTER: Connecting Rods

CHAPTER: Connecting Rods

Service Training Malaga

Service Training Malaga

CHAPTER: Connecting Rods

No marks on the top of the piston

CHAPTER: Connecting Rods

Service Training Malaga

Service Training Malaga

CHAPTER: Connecting Rods

CHAPTER: Connecting Rods

Service Training Malaga

CHAPTER: Connecting Rods

What do you see ?

CHAPTER: Connecting Rods

Rough surface, no plastic deformation

Brittle fracture due to

CHAPTER: Connecting Rods

Can indicate bearing failure

Service Training Malaga

CHAPTER: Connecting Rods

Heat discoloration, Thermal cracks

Bearing have spun

Service Training Malaga

CHAPTER: Connecting Rods

Joint have been lose

Service Training Malaga

CHAPTER: Connecting Rods

Normal stress raiser

Service Training Malaga

CHAPTER: Connecting Rods

What is the cause of the failure ?

Service Training Malaga

Service Training Malaga

CHAPTER: Connecting Rods

What do you see ?

CHAPTER: Connecting Rods