Failure analysis of a diesel engine piston-pin

Abstract A diesel engine piston-pin used in a truck was smashed in four when servicing. The longitudinal and transverse cracking happened on the failed piston-pin. The cracks initiated from the internal hole surface and propagated toward the external circle. The occurrence of beach marks or fatigue striations on the fracture surfaces of all crack origin regions indicates that fatigue fracture is the dominant failure mechanism of the piston-pin. The internal hole and external circle surfaces are specified to be carburized. The microstructure and the microhardness profiles on the external circle and internal hole surface regions were examined to determine the depth of the carburized layer. However, not only was no carburized layer found on the internal hole surface, but also the serious decarburization occurred on the surface region of the internal hole. Appearance of decarburization in the internal hole surface decreases intensely the fatigue strength of the internal surface so that the crack initiated from the internal surface and propagated toward the external circle, at last the fatigue fracture occurred. Improper carburizing technology is responsible for the appearance of the decarburization on the internal hole surface.