1. Ivan Ivanov “Asen Zlatarov” University - Burgas
Non-destructive methods for control and defectoscopy of automotive cylinder heads
Ivan Ivanov
“Asen Zlatarov” University - Burgas

2. Main methods
Pressure testing – with heat water; air pressure in heat water
Liquid Penetrant testing – penetrant, cleaner , white detector;
Magnetic testing – only for cylinder head made by cast iron

3. Main defects in cylinder heads
Cracks – in the valve bridge; the valve seat – the pre-combustion chambers or the swirl chambers; the valve seat – the nozzle bore; under the valve seat; other
Deformation
Corrosion in cooling system
Metal erosion damage

4. Experimental methods Pressure testing of cylinder heads
Liquid Penetrant testing with visible water washable penetrant Pentrix 100, white detector spray – Rivelex 200 and remover – Metaclean 300.
Before testing cooling system must be free of oil, water and other contaminants that may prevent penetrant from entering flaws

5. Results after Penetrant testing
Automotive cylinder head – BMW 2,5 TDS:
Cracks in 5th cylinder in valve bridge and valve seat – swirl chamber

6. Results after Penetrant testing
Automotive cylinder head – Renault 2.2TD - crack in the edge from bore of glow plug and swirl chamber

7. Results after Penetrant testing
Automotive cylinder head – Mercedes 2.5TD- crack in the valve seat – pre-combustion chamber; Metal erosion damage from steam, from coolant entering the combustion chamber.

8. Results after Penetrant testing
Automotive cylinder head – Fiat 1.9TD – crack in bore for pre- combustion chamber and moment of preparation for welding

9. Results after pressure testing
Automotive cylinder head – Mitsubishi 2,5 D - Crack in 4th cylinder in valve bridge; other cracks.

10. Conclusion
The first operation in the repair of automotive cylinder heads is testing for cracks. The quality of its implementation and the testing results influence the other technological operations and the main repair of the engine. The use of penetrant testing or pressure testing depends on the machinery and equipment of the firm, the engine diagnosis and the evaluation of the operator.