Measurement and Analysis of Microstructure in MAN B&W Marine Engine Cylinder Liners
(According to MAN Specification 0743668-3)

**Graphite Classification

Korea is a strong nation in shipbuilding.

However, more than 70% of marine engines are manufactured by MAN B&W.

The joint venture of MAN and B&W has been renamed MAN Energy Solutions, and it collects license fees for over 70% of the marine engines produced worldwide and in Korea.

When manufacturing marine engine cylinder liners, it is mandatory to pass the specifications set by MAN in order to supply them as official engine parts.

At INGPLUS, we provide modules to companies producing marine engine cylinder liners through measurement and analysis that meet MAN B&W’s standards.

All measurements and analyses are performed using our microscope measurement software, I-MEASURE.

1. Overview

The image analysis process for evaluating the microstructure of cylinder liners and piston rings follows the guidelines of MAN Energy Solutions.

Graphite Classification is a sub-program of Image-Pro Delta, which, in accordance with ISO 945, classifies detected graphite by size and calculates the area ratio for each graphite size class. It then outputs graphite distribution data and graphs.

A cumulative graph (S-CURVE) is generated based on the area of graphite detected by class. The ISO Reference No. corresponding to 50% area ratio is estimated and displayed on the graph. This represents the average graphite length and is indicated as a number between Reference No. 1 and 8.

Longer graphite corresponds to a lower number, while shorter graphite corresponds to a higher value.

Graphite Classification MAN Energy Solutions Compliance

2. Preparation of Measurement Image

• Prepare a polished specimen without etching.

• Use the LIVE STITCH program to acquire a sample image covering 4 × 6 fields (an area of approximately 36 mm²). Perform the stitching operation by turning the stage control knobs of the metallurgical microscope.

• In practice, a sampling area larger than 36 mm² (width × height) is acquired and then trimmed to the specified size.

Stitch Image                                   Cropped Image

3. Measurement

• Load the target image into the I-MEASURE screen.

• Press the Threshold button and adjust the Detect Graphite Slider to detect graphite.

• If the Median Filter option is checked, small objects (less than 5 µm) and image noise are removed before measurement

• When the Measure button is pressed, the measurement begins. The detected graphite is classified by size, and the area ratio for each graphite size class is calculated. Graphite distribution data and graphs are then generated.

This process takes time, so the messages Processing and Classifying are displayed on the screen. Once the classification of graphite by class is completed, each object is color-coded according to its class, and the measurement is finalized.

4. Report

• When the Report button is pressed, a lot number input window appears and the measurement result report is exported to Excel.
  The original image, measurement image, measurement data, and S-Curve graph are output, and both the original and result images as well as the Excel sheet are automatically saved in the designated folder.
  (Save folder: C:\MAN\Lot Number)
  
  

A test report that meets MAN specifications. This module is supplied to companies that actually manufacture cylinder liners for MAN engines.

*Hard phase Distribution*

1. Overview

• The image analysis process for evaluating the microstructure of cylinder liners and piston rings follows the guidelines of MAN Energy Solutions.
• Hard Phase Distribution is a sub-program of the image analysis software Image-Pro Delta, and in accordance with MAN Energy Solutions regulations, it is performed to investigate the area ratio and distribution of hard phases through the following procedure.
• Detect hard phases in the image analysis program and calculate the area fraction.
• Measure 240 fields on a mosaic image (approximately 36 mm²). Each single field has a size of 3 mm², and the measurement data of each field is plotted on a distribution graph, showing the Average (%) and the peak frame.
• Mark the area measured with the maximum fraction (occupancy) on the mosaic image with a boundary.

Hardphase Distribution MAN Energy Solutions Compliance

2. Preparation of Measurement Image

• Prepare a specimen deeply etched with 2% Nital.
• Operate the Live Stitch program to prepare a sample image covering 4 (horizontal) × 6 (vertical) fields (an area of approximately 36 mm²).
• Perform this operation by turning the stage control knobs of the metallurgical microscope.                                                                                                                                     In practice, a larger area than 36 mm² (width × height) is sampled and then trimmed to the specified size. 

Stitch Image                                     Cropped Image

3. Measurement

• Load the target image onto the screen.
• Press the Threshold button and adjust the Detect Hard Phase Slider to detect hard phases.

• When the Measure button is pressed, the measurement begins. A total of 240 fields are measured on the mosaic image, each single field having a size of 3 mm². The measurement data of each field are plotted on a distribution graph, showing the Average (%) and the peak frame. When the Measure button is pressed, the measurement begins. A total of 240 fields are measured on the mosaic image, each single field having a size of 3 mm². The measurement data of each field are plotted on a distribution graph, showing the Average (%) and the peak frame.

Hardphase Measured in Frames of 3mm²

• On the mosaic image, the area measured with the maximum fraction (occupancy) is outlined in red.

4. Option

• In the measurement options, you can select either continuous processing or step processing.

  For Continuous, the final results are displayed after all measurements are completed.

  For Step, the movement process of the measurement area is shown first, and the results are displayed afterward.

5. Report

• When the Report button is pressed, a lot number input window appears, and after entering the lot number, the measurement result report is exported to Excel.
  The original image, measurement image, measurement data, and occupancy distribution graph are output, and both the original and result images as well as the Excel sheet are automatically saved in the designated folder.
  (Save folder: C:\MAN\Lot Number) When the Report button is pressed, a lot number input window appears, and after entering the lot number, the measurement result report is exported to Excel.
  The original image, measurement image, measurement data, and occupancy distribution graph are output, and both the original and result images as well as the Excel sheet are automatically saved in the designated folder.
  (Save folder: C:\MAN\Lot Number)

MAN Energy Solutions Ident No : 0743668-3