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	Surface analyzer technology is used to determine how component forms and surface textures affect fuel and lubricant performance.

To help the automotive industry develop engine oils and lubricants that meet current and future requirements and challenges, Southwest Research Institute (SwRI) conducts detailed, precise studies of used and failed engine parts. SwRI uses state-of-the-art measurement equipment and skilled technicians to meet industry requirements for rapid, precise, and reliable data.

Micro Analyzer 2000 Surface Analyzer

The Fuels and Lubricants Research Division at SwRI uses surface analyzer technology in a variety of computer programs. The Micro Analyzer 2000 Surface Analyzer determines how varying component forms and surface textures affect fuel and lubricant performance in heavy-duty engines. Components studied include:

• Piston rings

• Pistons

• Cam lobe profiles

The analyzer measures wear and determines surface roughness on a variety of engine end-of-test (EOT) and buildup parts. Surface texture and waviness variations can be measured on selected areas of components, including:

• Cylinder liners

• Piston rings from heavy-duty diesel engines

• Cam profiles

Dorsey Ring Tension Machine

The Dorsey Ring Tension Machine measures piston ring tension in pounds-force at a preselected piston ring end gap. The gage will accept rings with a cylinder bore size from 87 mm to 189 mm and a maximum thickness of 6 mm. Ring tension determines the amount of wear and the amount of oil used in an engine during operation.

Mitutoyo Portable Surface Analyzer

The Mitutoyo Portable Surface Analyzer Surftest SJ-400 is designed to measure surface roughness, surface waviness, and steps. The SJ-400 has a 1.25-nm resolution and a stylus pressure of 0.75 mN. Maximum scanning distance is 50 mm and the analyzer is capable of measuring surface imperfections as large as 800 μm.

The hand-held unit runs on a computer laptop, enabling portability in laboratory environments. The surface analyzer measures surface roughness of a part prior to its use at the beginning of a test. Wear measured by the apparatus may indicate ring reversal wear in the top of a liner.

Engineers use the Dorsey Ring Tension Machine to study heavy-duty diesel engine piston ring tension as it relates to engine wear and oil consumption.		Using the Mitutoyo Portable Surface Analyzer, staff measure the roughness of the surface of a part before initiating a test to analyze wear rates.

Mitutoyo Measuring Microscope

The Mitutoyo Measuring Microscope measures:

• Ring thickness

• Groove width

• Lands

• Chamfers

• Ring grooves of pistons

The machine measures ± 1 m on the "X" and "Y" axes. The microscope uses cross hairs superimposed on a magnified image of a component set on a movable table with readout for both the "X" and "Y" axes.

Sunnen R1-9000 Electronic Rod Indicator

The Sunnen R1-9000 Electronic Rod Indicator measures rods for bend, twist and center-to-center length within 0.0005 inch, and measures a variety of connecting rods. Improperly aligned rods will affect rod bearing wear and may cause metals to appear in the engine oil, affecting overall engine operation.

The Mitutoyo Measuring Microscope allows researchers to analyze minute dimensions of ring thickness and groove width of a piston.		SwRI staff use an electronic rod indicator to ensure connecting rods are properly aligned.

Wilson Rockwell Hardness Tester

Surface hardness defines wear. SwRI engineers use the Wilson Rockwell Hardness Tester to check surface hardness on a variety of plastics (B-scale, HRB 20 and under) and metals (C-scale, HRC 20 to 60). The hardness tester is used on:

• Crossheads

• Tractor clutch forks

• Roller bearing races

• Ball bearings

Digital readout reports hardness relative to B- and C-scale. Engine parts have a small variance in hardness properties for optimal engine performance.

Mitutoyo Laser Scan Micrometer LSM-9506

The Mitutoyo Laser Scan Micrometer LSM-9506 is a noncontact system to measure object dimensions at a high speed using a highly directional scanning laser beam. The laser scan micrometer measures JASO M-354 diesel cam wear and Mitsubishi wear on cams, lobes, and tappets. The micrometer moves a scanning laser beam over a component piece and determines its dimensions to ± 0.0001 millimeter by measuring the duration in which the beam is obstructed by the piece. Cam lobe wear indicates an oil additive's ability to protect the lobes under shear force.

SwRI staff use the Wilson Rockwell Hardness Tester to characterize the hardness of materials determined through the depth of an indentation caused by specific load factors.		SwRI engineers utilize a laser scan micrometer—a non-contact, highly directional scanning laser beam—to measure object dimensions at high speed.

Mitutoyo Digiderm 746 Plating Surface Analyzer

The Mitutoyo Digiderm 746 Plating Surface Analyzer measures plating thickness to 0.001 mm and a maximum plating thickness up to 1.5 mm. Irregular surface plating can indicate abnormal flaking and/or abnormal wear of critical engine parts.

Electronic and Mechanical Scales

The electronic and mechanical scales measure in grams before and after a test, weights of:

• Rings

• Main bearings

• Valve hats

• Valve followers

The scales are accurate to 1/10 mg, 0.0001 g, and the mechanical scale is accurate to 0.00001 g. These scales are used to determine weight loss, which indicates wear on internal engine components.
SwRI staff use a plating surface analyzer to ensure uniform plating thickness.		Researchers use electronic and mechanical scales to determine weight loss of rings, main bearings and other engine parts.

Snap Gage

The snap gage measures various components such as cam lobes, heel to toe, before and after a test. Results are reported in metric, ± 1 micron, 0.001 mm. During normal engine operation, cam lobes are under intense and constant stress. Cam lobe wear indicates shear properties of an oil during engine operation. Cam lobe stress significantly changes overall engine operation.

Olympus Microscope

The Olympus Microscope magnifies images to 0.001 mm. Magnified images detail micropits in predetermined templates in diesel coolant tests. Micropitting indicates poor protection by the coolant.

A snap gage measures stress factors of items such as cam lobes, which can significantly change engine operation.		Researchers uses the Olympus Microscope to analyze micropits in templates, which can impact coolant properties.

For more information about our metrology capabilities, or how you can contract with SwRI, please contact Ben Weber at bweber@swri.org or call (210) 522-5911.

metrology.swri.org 

| Engine Lubricants Research Department | Fuels and Lubricants Research Division | SwRI Home |

Southwest Research Institute^® (SwRI^®), headquartered in San Antonio, Texas, is a multidisciplinary, independent, nonprofit, applied engineering and physical sciences research and development organization with 11 technical divisions.

December 28, 2012