Contents 5.1 Introduction 107 5.2 Gross heat losses 107 5.3 Prediction of local heat flows 107 5.4 Heat transfer at coolant side 109 5.4.1 Stationary surfaces—cylinder head and liner 109 5.4.2 Moving components—pistons 112 5.4.3 Establishing temperature maps 113 5.5 Thermal stress 113 5.5.1 Thermal stress failures 113 5.5.2 Materials 113 5.5.3 Strongbacked constructions 114 5.5.4 Calculation of thermal stress 114 5.6 Limiting conditions in operation 115 5.6.1 To meet lubrication requirements 115 5.6.2 For thermal strength 116 5.6.3 Fuel injector 116 5.7 Designing to meet thermal requirements 116 5.7.1 Cylinder head 116 5.7.2 Cylinder liner 118 5.7.3 Piston design 118 5.7.4 Injector cooling 118 5.8 Measurement of local temperature gradients and heat fluxes 119 5.8.1 Fixed thermocouples 120 5.8.2 Traversing thermocouples 120 5.8.3 Hardness recovery methods 120 5.8.4 Fusible plugs 120 5.9 Exhaust valves and seats 120 Acknowledgements 120 References 120 21761_05