1 < > MAN Diesel & Turbo Alberto Lapina

MAN Diesel & Turbo „Engineering the Future – since 1758.“

Exhaust valve spindles for marine diesel engines manufactured by hot isostatic pressing

Alberto Lapina, Harro Andreas Hoeg, Jakob Knudsen MAN Diesel & Turbo Tomas Berglund Sandvik Powder Solutions

Rune Møller, Jesper Henri Hattel Technical University of Denmark

2 < > MAN Diesel & Turbo Alberto Lapina

Challenge nr. 1

• How do you power the world trade to feed and cloth 7+ billions people?

• You need 50000+ ships • Container ships • Oil tankers • Iron ore carriers • Fruit juice tankers (yes, there is such

a thing!) • Etc. Etc.

• You need a power technology which is cheap, efficient and reliable

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The solution to challenge nr. 1: the two-stroke diesel engine

• Well-proven technology

• High efficiency

• Wide range of possible fuels (heavy fuel oil, diesel oil, natural gas, ethane, methanol, etc.)

• 3-80 MW power range depending on engine model

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Challenge nr. 2

• Fuel efficiency must increase to reduce costs & environmental regulations are getting more and more stringent

• The maximum pressure in the combustion chamber has doubled over the last 30 years

• The thermal loads have increased

• The exhaust valve spindle is experiencing high temperatures, since it has no active cooling!!

• Result: high hot corrosion rates of the spindle bottom.

5 < > MAN Diesel & Turbo Alberto Lapina

The current solution to problem 2: the Duraspindle™

• Stainless steel substrate

• Inconel 718 seat: high hardness after aging and cold deformation good wear resistance

• Inconel 625 bottom coating: high hot corrosion resistance

• Max allowed corrosion rate: 0. 4 mm/ 1000 hrs

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A possible new solution to problem nr. 2 The HIP spindle

316L buffer layer Stainless steel substrate

NiCr49Nb1 coating

• To be tested in service onboard ships up to 18000 hours (∼ 3 years)

Seat material

7 < > MAN Diesel & Turbo Alberto Lapina

Corrosion rate: State-of-the-art materials vs NiCr49Nb1

In this test, the new material gives only a marginal improvement over the state-of-the-art materials, because of relatively low temperatures Previous tests show differences in corrosion rates 4-5 times higher, in

engines with higher temperatures.

0

0,05

0,1

0,15

0,2

0,25

0 20 40 60 80 100 120 140 160

Cor

rosi

on ra

te (r

elat

ive

to N

iCr4

9Nb1

) /

mm

/100

0 hr

s

Distance from center of the spindle / mm

Nimonic 80A

HIP Inconel 625

MIG Inconel 625

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Phase evolution

Service T range

HIP T range

The material microstructure evolves to a new equilibrium state at service temperature Increase of fraction of α-Cr and formation of

Ni3Nb particles

AS HIPPED

1580 hrs at 700 °C

9 < > MAN Diesel & Turbo Alberto Lapina

Evolution of mechanical properties

0

5

10

15

20

25

30

35

400

500

600

700

800

900

1000

1100

0,00 500,00 1.000,00 1.500,00 2.000,00 2.500,00 3.000,00 3.500,00 4.000,00 4.500,00 5.000,00

Elon

gatio

n A5

/ %

Rp,

Rm

/ M

Pa

Hours at 700 °C

Rp and Rm decrease over the first few hundred hours, then stabilise

Rp

Rm A

10 < > MAN Diesel & Turbo Alberto Lapina

Performance of the new NiCr49Nb1 coating

• Corrosion resistance is improved (level of improvement depends on the type of engine and specific running conditions)

• The strength of the material decreases in the first few hundred hours but then stabilises.

• However there are two issues with this spindle design.

11 < > MAN Diesel & Turbo Alberto Lapina

Issue 1: Bending of the spindle

-3

-2,5

-2

-1,5

-1

-0,5

00 5000 10000 15000 20000

Cha

nge

in s

eat a

ngle

/ °

Service time / hours

#2 - 9 mm

#3 - 12mm

#4 - 12mm

The spindle bends upwards during service This occurs continuously over thousands of hours in service

12 < > MAN Diesel & Turbo Alberto Lapina

Issue 2: crack at inner seat circumference

13 < > MAN Diesel & Turbo Alberto Lapina

Issue 2: crack at inner seat circumference

• The step at the seat-316L is due to different corrosion rates of the two materials

• The step acts as a stress concentrator

• The bending of the spindle moves the contact point with the bottom piece toward the outer part of the seat area

• This increases the bending moment and so the stresses in the inner seat area.

• The bending induces the crack

316L buffer layer

Substrate

Seat

1 mm

14 < > MAN Diesel & Turbo Alberto Lapina

FE modelling: understanding the bending

High cycle thermal fatigue is excluded as a possible mechanism Low cycle thermal fatigue

(start-stop cycles of the engines) is modelled Significant TEC mismatch

between 316L and NiCr49Nb1 Main approximations:

Seat in NiCr49Nb1 Uniform temperature

field

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Thermal expansion coefficient mismatch

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Von Mises stresses at room T

Von Mises stresses increase slowly with the number of cycles

After 1st service cycle After 5th service cycle

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Radial stresses at room T

The NiCr49Nb1 is in compression at the center of the spindle The 316L buffer layer is experiencing tensile stresses Cmpressive stresses in the seat area are so high the material would experience

yielding

After 5th service cycle Tensile stresses

After 5th service cycle Compressive stresses

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Yielding

The 316L layer (and the seat area) are yielding

After 1st service cycle After 5th service cycle

19 < > MAN Diesel & Turbo Alberto Lapina

Calculated change in seat angle vs number of service cycles (up to 5 cycles)

-0,033

-0,046

-0,055

-0,062 -0,068

-0,08

-0,07

-0,06

-0,05

-0,04

-0,03

-0,02

-0,01

00 1 2 3 4 5 6

Cal

cula

ted

chan

ge in

sea

t ang

le / °

Number of service cycles

20 < > MAN Diesel & Turbo Alberto Lapina

Conclusions

• A hipped spindle with NiCr49Nb1 coating can operate successfully for thousands of hours

• The major challenges are the formation of cracks at the inner seat circumference and the bending of the spindle.

• A change in the design of the buffer layer (e.g. reduced thickness, change in shape) is currently considered, and other materials are under testing.

• Future simulation work will include temperature field in the spindle, and once experimental creep data for the materials involved are available, they will be implemented in the FE model.

21 < > MAN Diesel & Turbo Alberto Lapina

Acknowledgments

We thank Leonhardt & Blumberg and Wallenius Marine for allowing service testing

of the exhaust valve spindles onboard their ships.

Supported by EUDP (Energy Technology Development and Demonstration Program) funded by the Danish government.

22 < > MAN Diesel & Turbo Alberto Lapina

All data provided in this document is non-binding. This data serves informational purposes only and is especially not guaranteed in any way. Depending on the subsequent specific individual projects, the relevant data may be subject to changes and will be assessed and determined individually for each project. This will depend on the particular characteristics of each individual project, especially specific site and operational conditions.

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