Connecting Rods

www.dvd4arab.
com AFA I CHAPTER: Connecting Rods
Connecting Rods
Service Training Malaga 1

www.dvd4arab.com AFA I CHAPTER: Connecting Rods
Nomenclature

Loads Compressive and Tensile

Loads Bending

High Stress Areas

Manufacturing Grain flow
Forged Steel

Manufacturing
Heat treated to Rc 32
Shot peened

Manufacturing Rod Eye
Bushing pressed
and Broached

Manufacturing Big End
Matching

Normal Appearance Tin Flash

Normal Appearance

Normal Appearance
Cross hatch Pattern

Abnormal Conditions
• External Forces
• Bearing Failures
• Rebuild Errors
• Loose or Broken Bolts

Rod
Rod is Bent

Rod No marks on the top of the piston

Rod bearing

Rod Hydraulic Lock

Abnormal Conditions
• External Forces
• Rebuild Errors

Case 1. What do you see ?

Piston Rough surface, no plastic deformation
Brittle fracture due to

sudden impact load
L T
S U
RE
Big End Heat discoloration
Can indicate bearing failure

Big End Heat discoloration, Thermal cracks
Bearing have spun

Cap Fretting Corrosion
Joint have been lose

or overloaded

Shank Beach Marks
Fatigue Fracture
Beach marks
Normal stress raiser

What is the cause of the failure ?

Bearing failed causing vibration
overloading the shank


Big End Discoloration
Failed Bearing ?

Big End Fretting Corrosion, Ductile Fracture
Joint movement
L T
S U
RE
Cap Polishing around nut seating face

Bolt & Nut Damaged Treads

Bolt & Nut Damaged Treads

Nut Deformed

What is the cause of the failure ?

Abnormal Conditions
• External Forces
• Rebuild Errors


Rod Hinged, No Cross Hatch Pattern

Bearing Undersized

Rod Fatigue Fracture

Abnormal Conditions
• External Forces
• Rebuild Errors


Rod Hinged open, Ductile Fracture
Do not blame me !
L T
S U
RE
Rod Polishing, No Fretting

Rod Smoot, silky appearance
Ductile impact shear
L T
S U
RE
Bolt & Nut Damaged and stripped threads
Lose Nut


Bearing Undersized , Secondary damage No Failure

Someone have been
working on the engine

Rod Hinged, Ductile fracture
Look at the other side !
L T
S U
RE
Rod Fracture Smooth silky surface
Impact Shear
L T
S U
RE
Bolt Beach marks
No high stress area

Bolt Dent in the knurled area

Connecting Rod Problems
• Forging Laps
• Heat Treat
• Machining/ Shot Peening
• Assembly

Forging Lap


Bearing Damaged but not failed

Cap Dark, Rough with deformation
L T
S U
RE
Rod Beach marks, Ratchet marks
Subsurface

Rod Beach marks, Ratchet marks
Forging Lap

• Forging Laps
• Heat Treat
• Assembly

Quench Crack

Quench Crack

• Forging Laps
• Heat Treat
• Assembly


Rod Hinged, Ductile Fracture
I have told you before

don’t look at me !
L T
S U
RE
Cap Beachmarks

Cap Where is the initiation site ?

Cap
Bad shot peening

Connecting Rods

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www.dvd4arab.

com AFA I CHAPTER: Connecting Rods

Service Training Malaga 1

Service Training Malaga 2

Loads Compressive and Tensile

Service Training Malaga 3

Service Training Malaga 4

High Stress Areas

Service Training Malaga 5

Manufacturing Grain flow

Service Training Malaga 6

Service Training Malaga 7

Manufacturing Rod Eye

Service Training Malaga 8

Manufacturing Big End

Service Training Malaga 9

Normal Appearance Tin Flash

Service Training Malaga 10

Service Training Malaga 11

Service Training Malaga 12

Service Training Malaga 13

Service Training Malaga 14

Rod No marks on the top of the piston

Service Training Malaga 15

Service Training Malaga 16

Rod Hydraulic Lock

Service Training Malaga 17

Service Training Malaga 18

Case 1. What do you see ?

Service Training Malaga 19

Piston Rough surface, no plastic deformation

Brittle fracture due to

Big End Heat discoloration

Can indicate bearing failure

Service Training Malaga 21

Big End Heat discoloration, Thermal cracks

Bearing have spun

Service Training Malaga 22

Cap Fretting Corrosion

Joint have been lose

Service Training Malaga 23

Shank Beach Marks

Normal stress raiser

Service Training Malaga 24

What is the cause of the failure ?

Service Training Malaga 25

Case 2. What do you see ?

Service Training Malaga 26

Big End Discoloration

Service Training Malaga 27

Big End Fretting Corrosion, Ductile Fracture

Cap Polishing around nut seating face

Service Training Malaga 29

Bolt & Nut Damaged Treads

Service Training Malaga 30

Bolt & Nut Damaged Treads

Service Training Malaga 31

Service Training Malaga 32

What is the cause of the failure ?

Service Training Malaga 33

Service Training Malaga 34

Case 3. What do you see ?

Service Training Malaga 35

Rod Hinged, No Cross Hatch Pattern