Forensic investigation of piston assembly–cylinder liner failure in a heavy-duty diesel engine of a vibratory roller: A case study

Diesel engine failures have been extensively investigated. However, research specifically addressing failures of roller diesel engines operating under harsh and variable conditions remains limited. This study reports a case of piston assembly-cylinder liner failure in a heavy-duty roller diesel engine that recurred eight years after a major overhaul. The aim is to identify the root causes of failure to prevent engineering delays and economic losses. Unlike previous studies that focused on isolated components, this work conducts a comprehensive investigation covering the piston body, piston rings, piston skirt, connecting rod bearings, and cylinder liner. To elucidate the failure modes and mechanisms, multiple experimental analytical methods were employed, including metallographic examination, chemical analysis, visual inspection, and scanning electron microscopy. The results reveal that the failure was jointly driven by a triggering mechanism (insufficient maintenance), a dominant mechanism (abrasive and adhesive wear), and several secondary mechanisms including corrosive wear, cavitation erosion, and fatigue spalling. Finally, we have proposed targeted corrective actions and maintenance recommendations to prevent recurrence of such failures. The article should be of broad interest to the global engineering community, as early failure of construction machinery remains a critical concern.