Valves

Lion DVD
AFA I
CHAPTER: Engine Valves
Engine Valves
Service Training Malaga
In this module we will learn how to analyze valve failures.
Lion DVD
AFA I
In This Presentation
Nomenclature
Function
Materials
Manufacturing
Operation
Normal Appearance
Failure Analysis
During operation con rods experience compressive and tensile loads during
combustion and intake strokes.
Lion DVD
AFA I
Nomenclature
Valve nomenclature includes stem, keeper grooves,

inertial weld, fillet radius, head and hardfacing.
Lion DVD
AFA I
Valve Functions
Control Gas Flow
Seal Pressure
Withstand Heat
Withstand Acid
Endure Cyclic Loading
Provide Replacement
Valves are primarily used to control the flow of air and exhaust gasses into and out
of the cylinder.
They must be able to withstand high temperatures and corrosive conditions during
millions of load cycles and they are a maintenance item which may need to be
remanufactured at certain maintenance intervals.
Lion DVD
AFA I
Material
Two Piece Valves
Head austenitic stainless steel

Stem consists mild low carbon steel
Almost all Caterpillar valves in use today are friction welded two piece valves
consisting of a head made from special alloy steel and a stem consisting of a low
alloy steel. This etched cross section shows the different materials.
Lion DVD
AFA I
Manufacturing
Hardening
Stems hardened to Rc 40
Keeper groove induction
hardened to Rc 55
A closer look at the tip end shows the keeper grooves on a typical valve. Valve
stems are heat treated to about Rc 40 to prevent wear and the keeper grooves are
then induction hardened to Rc 55 to provide extra fatigue strength and wear life.
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Manufacturing
AFA I
Hard Facing
Forged stainless
steel
Hard facing high
alloy material
The valve head is made from austenitic stainless steel by forging. The flow lines
five the head increased toughness. The head is then heat treated to final hardness
and strength. Notice the area of hard facing surrounding the circumference of the
valve head.This is a welded deposit of high alloy material that resists wear against
the valve seat.
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Manufacturing
AFA I
Friction Welding
The stem and head are joined by a process called friction welding. The acid etch
shows the joint very clearly.
The darker metal is magnetic while the lighter material is only very slightly
magnetic.
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Manufacturing
AFA I
Friction Welding
The stem is inertial or friction welded to the head. In

this process a free spinning flywheel containing a fixed
amount of energy holds the stem that is then pushed
against the valve head. The energy of the flywheel is
transferred into frictional heat and causes melting and
adhesion of the stem to the head. The weld is completed
when the flywheel stops. All inertial welds are checked
for soundness.
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Manufacturing
AFA I
Friction Welding
Find the weld with

the help of a Magnet
10
A magnet can be used to determine the weld location on a new or used valve. This
is also a good way to determine if a valve failed at the weld.
If one side is magnetic and the other side is not, the weld failed.
10
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AFA I
Operation
11
Valves will function correctly only if they are installed properly and aligned with
the valve seat inserts in the cylinder head.
This means the valve guides must be properly positioned in the cylinder head.
During operation the welded area of the valve stem remains inside the valve guide
as it cannot withstand the higher exhaust temperatures and corrosive exhaust
conditions.
11
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AFA I
Operation
Spring Force
12
Valves experience loading from the valve spring.

This produces tension in the stem on closing and compression at the keeper grooves
on opening.
12
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Operation
AFA I
Valve Closing
Tensile load in
valve stem
13
When the valve sits down on the seat upon closing it produces a tensile load
throughout the entire length.This is why it is important to keep valve lash adjusted
properly. This prevents shock loading the valve on seating.
13
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Operation
AFA I
Combustion Pressure
Bending stresses
in under head fillet
14
Probably the most severe stress the valve experiences is bending due to combustion
gas loading.
This causes a lot of stress on the valve under head fillet.
14
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AFA I
High Temperature Road signs

Thermal Cracks in Fillet Radius
Dished Valve Head
Oxidation, Scale Buildup
Many Valves Damaged
15
Probably the single largest cause of valve failures is overheating. This leads to loss
of strength in the under head fillet which is a high stressed area.
Lets see what the road signs of high temperature operation look like.
15
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AFA I
Abnormal Conditions
High Temperature
Thermal Fatigue Crack
16
Notice the cracking in the under head fillet. These cracks are caused by excessive
exhaust temperatures. They are thermal fatigue cracks and can lead to a valve head
failing. We should attempt to discover what is causing the excessive temperature.
16
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AFA I
Abnormal Conditions
High Temperature
Dishing or tuliping
17
Some inlet valves are not made of the type of alloy metal that is used in exhaust
valves.These valves will not withstand excessive temperatures for very long without
drooping. This valve is actually dish shaped or curved due to high temperature
operation.
17
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AFA I
Abnormal Conditions
High Temperature
Oxidation and
Decomposition
18
This valve head shows oxidation and decomposition of the valve head alloy. This
indicates excessive high temperature operation for extended periods.
18
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AFA I
Abnormal Conditions
High Temperature
Discoloring
19
If severe temperatures persist, sometimes the valve cannot remove the heat and it
travels up the stem into the valve guide discoloring most of the valve stem.
19
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AFA I
Abnormal Conditions
High Temperature
Chordal Fractures
20
As valves continue to operate at excessive temperatures the under head fillet starts
to weaken and may experience fracture.
This type of failure is called chordal fracture.
20
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AFA I
Abnormal Conditions
High Temperature
Chordal Fractures
21
We can see a smooth fracture with beach marks indicating this is a fatigue fracture
which grew over time.
The initiation site is at the top.
21
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AFA I
Abnormal Conditions
High Temperature
Chordal Fractures
22
Looking at the other side of the fracture we see some ratchet marks extending to the
surface indicating fatigue started on the valve surface.
The oxide deposits on the surface are indicators of excessive high temperature
operation.
Most chordal fracture is caused high temperature operation for extended periods.
22
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AFA I
Abnormal Conditions
Misalignment
Rotating bending stresses
23
Remember that valves must be properly aligned to work correctly. Lets examine
what could happen if the valve guide and the valve seat insert are not on the same
central axis. The valve face will contact the insert harder on one side as it
rotates.This will produce rotating bending stress in the valve stem. Under these
conditions, the valve usually fractures in the stem.
23
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AFA I
Abnormal Conditions
Misalignment
Ratchet Marks
Ratchet
marks
24
Looking at this fracture we see ratchet marks around the valve stem circumference
and beach marks growing inwards.
Final fracture is in the center.
This is typical rotating bending fatigue caused by misalignment between the valve
and valve seat insert.
24
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AFA I
Abnormal Conditions
Bending Fatigue
Ratchet Marks
Beach Marks
25
Looking at this fracture what do we see? Beach marks and ratchet marks indicating
a fatigue crack started at lower right and grew to final fracture at upper left.This is
typical bending fatigue.What might cause this.If the valve head becomes bent, the
valve face only contacts the seat at one point putting a constant bending load on the
stem.
25
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AFA I
Camshaft Nomenclature
26
To prevent the valve from seating too rapidly or not at all, the cam lobe is designed
to gently lift the valve off the seat.
Accelerate it rapidly to full open position, slow it down until it stops at full open,
and then reverse the process.
This requires careful and accurate valve lash adjustment and good maintenance
practices.
If valve lash is not adjusted correctly, shock loading of the valve on the seat can
occur leading to fracture in the valve stem.
26
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AFA I
Abnormal Conditions
Lash Adjustment
27
This is the typical appearance of a valve stem fractured due to improper lash
adjustment.
27
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AFA I
Improper Lubrication Root Causes

Guide to Loose
Guide to Tight
Wrong Oil Type/Viscosity
Valve to Hot/ Cold
To Much/Little Oil
28
There are many reasons why improper lubrication of the valve in the guide may
occur.
The end result is usually valve sticking.
28
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AFA I
Abnormal Conditions
Piston Contact
Bent valve may indicate valve

was sticking in guide
29
When valves are bent but not broken, this may indicate the valve was sticking in the
guide and hit by the piston.
29
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AFA I
Abnormal Conditions
Piston Contact
Ductile or Brittle fracture

due to impact load
30
Valves broken due to impact by the piston should show a ductile or brittle fracture
due to the impact load.
30
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AFA I
Abnormal Conditions
Piston Contact
Brittle fracture
31
What do we see here? Sparkles, rough surface, no plastic deformation. This is a

brittle fracture due to a single impact load.
The valve and piston collided. We need to discover why the valve was open when
the piston came up.
31
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AFA I
Abnormal Conditions
Piston Contact
The rest of the parts
32
We should inspect the remainder of the valve train.

Bent push rods, broken lifters and valve spring coil contact all indicate the valve
was struck hard by a piston.
32
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AFA I
Abnormal Conditions
Piston Contact
Brittle fracture
33
Note the road signs of brittle fracture and impact load on this follower.
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AFA I
Abnormal Conditions
Piston Contact
Keeper may be damaged

made of low carbon steel
34
Keepers may be damaged also due to impact since they are made from soft low
carbon steel.
34
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AFA I
Abnormal Conditions
Piston Contact
Cracks in retainers
35
Cracks may be found in retainers too if impact or shock loading of the valve train
occurred.
35
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AFA I
Abnormal Conditions
Piston Contact
Full coil contact
36
Full coil contact of valve springs are good indications of shock load on the valve
train but may also be evidence of over speed.
36
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AFA I
Abnormal Conditions
Piston Contact
37
Most springs have paint markings to identify the spring supplier. Note how the paint
has been removed where the spring coils contact. This indicates the spring was
compressed solid and we should attempt to find out why.
37
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AFA I
Abnormal Conditions
Guttering
Caused by valve face deposits

Mostly common in Gas engines
38
Another way valves fail is by guttering. This is more common in gas engine valves
but occurs anytime valve face deposits form. Deposits often are brittle, crack and
form leakage paths for hot exhaust gasses.
38
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AFA I
Abnormal Conditions
Guttering
Right OIL must be used to

prevent deposit formation
39
Eventually the gasses act like a cutting torch and gutter the valve. This is why it is
extremely critical to keep valve faces and seat inserts free of deposits. The right oil
must be used to prevent deposit formation.
39
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AFA I
Abnormal Conditions
Guide Wear
Improper Lubrication
Poor lube oil quality
Corrosive environment
40
Improper guide lubrication or poor lube oil quality can lead to excessive guide wear.
Worn guides allow valves to slap against seats and can contribute to valve failure.
40
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AFA I
Abnormal Conditions
Corrosive Environment
41
Splitting open the guide in the previous picture shows the severe corrosive attack
that has removed all the knurling in the guide and left oxide deposits.
41
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AFA I
Abnormal Conditions
Corrosive Environment
42
This same corrosive condition can lead to accelerated valve face and seat wear.
42
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AFA I
Abnormal Conditions
Foreign Material
43
Another abnormal condition sometimes seen on valves occurs only on the head area
facing the piston.
This appearance is caused by foreign material between the valve and the piston.
Look for the material embedded into the piston top if the engine has aluminum
pistons.
43
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AFA I
Parts Problem
Friction Weld Failure
Handling Damage
Material Strength
44
Very few valve failures are due to parts problems but lets look at some of the more
common ones.
44
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Parts Problem
AFA I
Friction Weld Failure
45
This valve failed at the friction weld due to poor weld quality.
Note the swirled condition of the metal.
Remember that a magnet can be used to quickly confirm that this is a weld failure.
45
Lion DVD
Parts Problem
AFA I
Valve head and stem not aligned
46
Once in a while the valve head is not correctly aligned with the stem.
This will be obvious if the seat will not grind completely.
46
Lion DVD
AFA I
Parts Problem
Spring Problems
Fail along the inner diameter

Due to load is highest there
47
Occasionally valve spring wire may have inclusions present. This can lead to
smooth fatigue fracture of the valve spring. The spring load is highest along the
inner diameter of the spring and this is the place where most fatigue failures will
start.
47

Valves

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Valves

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Lion DVD

CHAPTER: Engine Valves

In this module we will learn how to analyze valve failures.

CHAPTER: Engine Valves

CHAPTER: Engine Valves

Service Training Malaga

Valve nomenclature includes stem, keeper grooves,

CHAPTER: Engine Valves

CHAPTER: Engine Valves

Two Piece Valves

Head austenitic stainless steel

Service Training Malaga

CHAPTER: Engine Valves

Service Training Malaga

CHAPTER: Engine Valves

Service Training Malaga

CHAPTER: Engine Valves

Service Training Malaga

Service Training Malaga

CHAPTER: Engine Valves

The stem is inertial or friction welded to the head. In

CHAPTER: Engine Valves

Find the weld with

Service Training Malaga

CHAPTER: Engine Valves

Service Training Malaga

Service Training Malaga

CHAPTER: Engine Valves

Valves experience loading from the valve spring.

CHAPTER: Engine Valves

Service Training Malaga

CHAPTER: Engine Valves

Service Training Malaga

CHAPTER: Engine Valves

High Temperature Road signs

Service Training Malaga

CHAPTER: Engine Valves

Thermal Fatigue Crack

Service Training Malaga

CHAPTER: Engine Valves

Service Training Malaga

CHAPTER: Engine Valves

Service Training Malaga

CHAPTER: Engine Valves

Service Training Malaga

CHAPTER: Engine Valves

Service Training Malaga

CHAPTER: Engine Valves

Service Training Malaga

CHAPTER: Engine Valves

Service Training Malaga

CHAPTER: Engine Valves

Rotating bending stresses

Service Training Malaga

CHAPTER: Engine Valves

Service Training Malaga

CHAPTER: Engine Valves

Service Training Malaga

CHAPTER: Engine Valves

Service Training Malaga

Service Training Malaga

CHAPTER: Engine Valves

CHAPTER: Engine Valves

Improper Lubrication Root Causes