Material for Bedplates

Cast Iron (C .I.) absorbs and dampens vibration.

Mild Steel (M.S.) plates or castings welded together are cheaper and lighter.
This is a structure that may be made of cast iron, prefabricated steel, cast steel, or a hybrid arrangement of cast steel
and prefabricated steel.
▪ Transverse Girder - Cast iron
▪ Longitudinal Girder - Mild steel
Frame:
Frames are provided for supporting the engine mountings, and an individual frame is fitted to each cross girder. Frames
are made up of Mild Steel Plates and Tubes.
Holding Down:
The engine bed plate is supported on a series of chocks made up of Cast Steel / Epoxy Resin and the holding down
bolts passes through the bed plate, chock, and tank top plating made up of UTS Steel.
Guide:
Guides are provided in the cross head assembly. They have two main parts, and they are made up of the following
materials:
Guide Bar -Mild Steel / Cast Iron
Guide shoe- White Metal Lined

Piston Materials
Crown - Aluminium or cast steel (4-stroke).
Crown - Cast chrome nickel molybdenum alloy steel (2-stroke).
Skirt - Si-Aluminium alloy (4-stroke) or cast iron.
Rod - Forged steel.
Wear Ring - (Lead-Bronze)
Piston Ring Material
The piston ring is made of Cast Iron.
Grey Cast Iron gives better wear and scuffing resistance.
Nodular chromium-plated malleable Cast Iron gives better fatigue resistance.
Carbidic malleable Cast Iron gives better fatigue and wear resistance.
R.VK with AL-Bronze as a running-in coating.
Materials used for piston required similar properties to those for cylinder liners and cylinder covers.
Properties of Piston Crown material:
1. High mechanical strength to withstand high gas load.
2. Long fatigue life to survive the fluctuating mechanical and thermal stress.
3. High thermal conductivity and low co-efficient of expansion.
4. High surface property i.e. hardness, anti-corrosive.
5. The metal must resist high temperature creep, corrosion and erosion.
Properties of Piston Ring material:
1. Highly mechanical strength and good tension properties.
2. Elasticity and wear resistance with low-friction.
3. Must be corrosion resistance with low- friction.
4. Must be corrosion resistance and resistance against high temperature.
5. Self-lubricating properties.
6. Must readily transfer heat and compatible with cylinder material.
7. Compatible with piston for thermal expansion to maintain ring groove clearances.

Stuffing box materials

Housing - Cast iron or cast steel.
Rings - Cast iron or brass or bronze or PTFE
Upper Rings - Bronze Alloy
Lower Rings - Cast Iron Alloy
Lamellas - Cast iron or carbon
LINER Materials
Requirements
Good casting characteristics (Cast Iron is good, while Cast Steel is prone to defects).
 High strength, high thermal resistance and high corrosive resistance.
Cylinder heads are made of:
Composite structure i.e. Grey Cast Iron which has a good tensile strength and casting characteristics
Molybdenum Steel for elasticity and strength (0.3 % C, Mo 1.5%).
♦ Steel casting or forging of deep section, single piece, bore cooled and machined at sealing faces.
Cylinder heads materials Properties:
1. Must be of sufficient strength to withstand the gas load at maximum pressure.
2. Resist bending and be symmetrical in shape.
3. Have a rate of thermal expansion compatible with adjacent parts and transfer heat readily
Cylinder head bolt- High UTS Steel
Tie bolt - High UTS Steel.
Properties of Cylinder Liner Material:
1. Material for liners must provide adequate strength and fatigue life.
2. Resist abrasion and corrosion and must readily transfer heat.
3. Be able to retain a film of lubricating oil on working surfaces.
4. Have a rate of thermal expansion compatible with adjacent parts.
To meet these requirements, liners are cast in pearlitic grey cast irons to which alloying elements such as vanadium
and titanium are added to enhance strength, wear, and corrosion resistance. Chrome plated liners have extended
life, but the initial cost is higher.
Chrome plated piston ring must not be used with chromium plated liners

EXHAUST Valve Materials

Requirements are creep resistance at high temperatures; corrosion and oxidation resistance; wear resistance;
erosion resistance; machinability; high temperature strength; compatibility with valve guide materials; impact
resistance and surface hardness.
Valve
Nickel based alloy (0.1 C, 0.1 Fe, 15 Cr, 1.0 Ti, 5 Al, 20 Co, 4 Mo, remainder Ni)
Precipitation hardened steel (0.5 C, 25 Cr, 5 Ni, 3 Mo)
Austenitic steel (Cr & N i 25 %) Si-Chrome steel (3 Si, 9 Cr).
Valve Face
‘Stellite’ : 2C, 50 Co, 20 Cr, 18 Mo, 10 Tungsten
Valve Seats
‘Stellite’ coating, since seats are also prone to corrosion and erosion.
Valve Cages
Cast Iron provides easy manufacture and compatibility with guide material. Valve Guide ‘Pearlite’ Cast Iron.
EXHAUST Valve Materials(SHORTCUT)
Spindle - Nimonic Material
Lid - Nimonic Material
Seat - Stellite Material
Cage - Pearlitic Cast Iron
Guide - Pearlitic Cast Iron
Bush - Bronze
Crankshaft Materials
High carbon steel (0.35 to 0.45 C) for slow speeds.
High carbon steel with alloys for medium high speeds.
Chromium, tungsten, nickel and magnesium alloys are used in percentage of 1.5 % each.
Materials: These are some of the commonly used materials to build the crank shaft.
Low alloyed Cr –Mo steel which has tensile strength (590-680) N/mm2
Unalloyed Carbon Steel (Normalized).
Mild Steel (Cast throw).
Carbon Steel (forged or cast).
Nickel steel (forged).
Properties of Crank Shaft materials:
1. Besides strength, the material should have a high endurance limit to fatigue failure.
2. The material should be capable of good surface finish.
3. Must be hardened to resist wear of journals and crank pins.
 4. Must be tough to carry load.
5. Must be rigid to resist bending of the shafts.
6. But it should confirm bearing line alignment

Chain Materials
(1) Link plates :Cr-M o steel
(2) Pin : Hardened steel (interference fit into outer link plate)
(3) Rollers : Alloy steel
Bearing Materials
(1) While Metal Bearings :
Anti-friction, tin-based, white metal alloys (called Babbitt) consist of :
Tin (Sn) 88 % Soft matrix to allow for small changes in alignment between bearing and journal.
Antimony (Sb) 8% Hard wear resistant cubes to absorb and transmit load.
Copper (Cu) 4% To segregate and hold antimony cubes in a tin matrix.
(2) Thin Wall Shell Bearings:
These bearings are usually of tri-metal type, having 3 main layers and a steel backing shell,
1“ layer (Flash) -1 micron thickness of lead / tin for corrosion before installing bearing
2“ layer (Overlay) -20 micron thick white metal
3"1 layer (Interlay)- 5 micron thick nickel dam helps to reduce corrosion of the white metal 2“ layer.
4th layer (Lining) -1 mm thick lead / bronze
Shell (Bottom) -It is a steel backing shell for shape and support
T/C Materials
Turbine Wheel, Nozzle Ring, Rotor Shaft and Blades : Nimonic 90 (Nickel-Chrome alloy) (Ni 75%, CO 18%, Ti 3%, A1 2%,
C r 2%) These have impact resistance, strength, thermal stability and creep resistance at high temperatures of
continuous operation upto 650 deg. C.
Turbine Casing : Cast Iron with corrosion preventive plastic coatings in case of water cooled turbochargers
Connecting rod bolt- High UTS Alloy Steel
Camshaft- Steel Alloy with Hardened surface

Air compressor Valve Materials

Body - Steel (0.4 % C) with hardened seat area.
Plates - Steel (Ni or Cr or M o-Alloy)
Springs - Hardened alloy steel.
chocking materials
epoxy resin
The Air Start Valve
The body of the valve could be of mild steel, the spindle of high tensile or stainless steel, and the valve and seat could
have the contact faces stellited or hardened
State, with reasons, the materials used for the different parts of the piston described in Q.6(a) including ring
material. (4)
Piston Crown: Chrome Molybdenum Steel. Maintains strength and resists corrosion/erosion at high temperatures. As
previously stated, this piston as a layer of inconel welded to the hottest part of the crown. Skirt: Cast Iron. Cast iron
contains graphite, a lubricant. In theory the skirt should not touch the liner; in practice it does. Cast iron has good oil
retention qualities, and its rate of expansion is the same as the liner in which it runs, allowing minimal clearances.
Rings: Rings are harder than the liner in which they run, to give them a reasonable life. Pearlitic grey cast iron
containing molybdenum, chromium, vanadium titanium, nickel and copper.
Sketch a section through the bedplate and A frame of a large slow speed engine, identifying parts, method of
construction and materials. (8)
state the materials used for top end bearings and guide shoe surfaces. (2)
The top end bearings are subject to a high loading. The bearing material must be able to resist this pressure without
breaking up. The material used is a tin aluminium alloy bonded to a steel backing. The material for the guide shoe
surfaces is a good quality babbit metal which is a white metal containing tin, antimony and copper.
c. State the materials used for the seat and valve described in
✓ The valve spindle and seat have to withstand high temperatures ( ~540ºC) maintain strength and resist erosion
and high temperature corrosion due to deposits caused by vanadium and sodium in the fuel.
✓ The valve spindle head is subject to harsher conditions as it is not permanently cooled. The replaceable seat
is made from a surface hardened molybdenum steel alloy.
 ✓ The valve spindle is either manufactured from a heat resisting alloy steel with a layer of stellite welded onto
the seating face, or the valve head is made from a nimonic alloy which is friction welded to an alloy steel
spindle.
state, with reasons, why some pistons are of composite construction, indicating the materials used for EACH part;
(4)
✓ Pistons for medium speed trunk piston engines designed to burn a distillate fuel can be made of either cast
iron or aluminium alloy.
✓ However when the engine is designed to burn residual fuels, these materials will not withstand the higher
temperatures at which residual fuels burn, leading to weakening and erosion of the piston crown.
✓ Because of this the pistons will be of composite construction comprising of: An alloy steel crown containing
molybdenum and chromium which gives increased strength and resistance to corrosion at high temperatures.
✓ A skirt manufactured of either cast iron or aluminium alloy (cast or forged).
✓ The cast iron has good wear resistant and self-lubricating properties, and a coefficient of expansion the same
as the liner, giving approximately the same clearance across the operating range.
✓ The alloy piston is lighter, leading to reduced stress reversal on bottom end bolts because inertia whip loading
is less, but because the coefficient of expansion is greater, increased manufacturing clearances between skirt
and liner lead to piston slap at light loads.
modern materials permit increase of engine power without the limitations formerly imposed on exhaust
temperatures; (4)
✓ Assuming the efficiency of the engine is at an optimum, the power developed by an engine cylinder is
dependent on the mass of fuel burnt per cycle and the number of cycles per second.
✓ The fuel must also have enough time to burn completely.
✓ It must be appreciated that residual fuels burn at a higher temperature than the distillates, and also contain
vanadium and sodium which when burnt can cause corrosion at high temperatures.
✓ To increase the mass of fuel burnt, the mass of air supplied must be increased, which means that the pressure
of the combustion air must rise or the diameter of the cylinder must get larger.
✓ The increases in size and the higher peak pressures will mean that the hoop stresses in the cylinder liner and
the bending stresses in the piston crown will increase, meaning that the thickness of the material used must
be increased.
✓ The surface temperature of the components will rise which will lead to a weakening of the material and an
increase in thermal stress.
✓ Unless the surface temperature of the liner below the top ring can be kept under190°, the cylinder oil will burn
off.
✓ The piston crown temperature must be kept low enough (below 400°) to prevent weakening of the material
and subsequent erosion by the combustion gases.
✓ Piston crowns and cylinder heads are made of heat resisting alloy steel containing chromium and molybdenum
to increase strength and resist corrosion at high temperatures, whilst cylinder liners are of high grade cast iron
with similar alloying elements.
✓ 'Exhaust temperatures' are only a guide, the gauge is reading an average over the whole cycle, not the
temperature of the exhaust gas.
✓ Because the exhaust valve is the hottest component in the cylinder due to difficulties with cooling, it must be
made from a material which retains its strength and resists corrosion, which is why nimonics are sometimes
used.
✓ To sum up, although modern materials, together with design improvements especially in turbocharging have
led to engine powers being increased, attention must be paid to adequate cooling and lubrication.
✓ The temperature of the exhaust gas is still used as a guide to operating conditions and as a limiting factor.