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Heavy Vehicle Propulsion Materials FY 2003 Progress Report G. Life Prediction of Diesel Engine Components H. T. Lin, T. P. Kirkland, A. A. Wereszczak, M. K. Ferber, and M. J. Andrews* Oak Ridge National Laboratory P. O. Box 2008, MS-6068 Oak Ridge, TN 37831-6068 (865) 576-8857; fax: (865) 475-6098; e-mail: linh@ornl.gov *Caterpillar, Inc. DOE Technology Development Area Specialist: Dr. Sidney Diamond (202) 586-8032; fax: (202) 586-2476; e-mail: sid.diamond@ee.doe.gov ORNL Technical Advisor: D. Ray Johnson (865) 576-6832; fax: (865) 574-6098; e-mail: johnsondr@ornl.gov Contractor: Oak Ridge National Laboratory, Oak Ridge, Tennessee Prime Contract No: DE-AC05-00OR22725 Objectives • Generate database and characterize damage mechanisms of candidate advanced ceramics and intermetallic alloys. • Apply and verify probabilistic life prediction and component design and verification for advanced diesel engine components. Approach • Evaluate the dynamic fatigue and rotary bending fatigue performance of candidate silicon nitride ceramics and titanium aluminide (TiAl) alloys at elevated temperatures in air before and after long-term exposure to simulated engine environments and before and after engine field tests. • Characterize the evolution and role of damage mechanisms and changes in microstructure that are linked to the long-term mechanical performance and reliability of ceramics and intermetallic alloys. • Use life prediction codes to predict the probability of failure and reliability of complex-shaped components subjected to application conditions. Accomplishments • Completed dynamic fatigue tests at temperatures of up to 1000°C in air for a commercial-grade silicon nitride, SN147-31N, purchased from Ceradyne, Inc. • Completed flexural stre