10. Block and Head Development

The concepts of reliability and durability were previously introduced in Chap. 3. That chapter was introduced with the example of the cylinder head to emphasize the importance of ensuring the durability of such major structural components. In this chapter discussion returns to the cylinder block and head, applying the concepts of Chap. 3 to the durability validation of these components. Both the cylinder block and cylinder head are expected to perform without failure for the engine’s life to overhaul. In automobiles the expectation is extended to include reuse in at least one engine overhaul and in heavy-duty applications to several overhauls. This expectation translates into one of an extremely low failure rate (less than one in many thousands) after many miles or hours of operation. If this expectation is not met the engine quickly gains a bad reputation from which it is extremely difficult to recover. This is especially devastating when one considers the investment in tooling for a new engine. A battery of tests and analysis must be devised to absolutely ensure that these durability expectations are met—an extremely challenging endeavor, and a critical path in the timeline of engine development.