Simulation-Based Thermal Fatigue Validation Test Development for Exhaust Manifold

Abstract Exhaust manifolds in diesel engines undergo continuous thermal cycle loading of varying thermal cycles with different mean, amplitude, and rate of temperature change created by application duty cycles. This makes analysis and testing of the exhaust manifold to meet the thermal mechanical fatigue life expectation of different applications challenging. In this paper, a simulation-based product development approach, which uses application duty cycles, simulation models of different capabilities, including three-dimensional Finite element simulation model, one-dimensional (1D) physis-based damage model to develop an abusive thermal cycle engine test for validating exhaust manifold, is presented.