Experimental observations of engine piston damage induced by knocking combustion

Abnormal combustion leads to a significant increase in combustion speed, pressure and temperature at the surfaces enclosing the combustion chamber. Severe and lasting knock or pre-ignition can permanently damage and, in many cases, destroy engine pistons, due to very high and localised thermomechanical stresses. The deleterious effects of abnormal combustions have led car manufacturers to set extremely precautionary thresholds in spark advance calibration (in terms of temperatures and pressures) of turbocharged spark ignition direct injection engines, often limiting engine performance and efficiency. Since the mechanisms of piston damage due to abnormal combustion are not currently fully understood, the aim of this study was to characterise its effects on Al forged pistons. The more suitable characterisation techniques were evaluated. The results highlighted that roughness measurements, as well as visual, optical and scanning microscopy analyses on specific zones of the top land and piston crown are useful techniques to qualitatively relate piston damage to combustion regime. Moreover, a significant quantitative relationship was observed between the MAPO (Maximum Amplitude Pressure Oscillations) index and residual piston hardness.