This investigation was aimed to investigate the effect of Exhaust Gas Recirculation (EGR) on wear of in-cylinder engine parts. EGR setup was fabricated for a two cylinder, air cooled, constant speed direct injection CI engine. Test setup was run for 96 hours with fixed loading cycles in two phases; normally operating condition (i.e. without EGR) and with 25% EGR rate. Addition of wear metals in the lubricating oil was investigated. Higher wear metal concentrations were found in the lubricating oil of EGR operated engine, which indicates higher wear of various engine parts. Weight loss of piston rings used in both the phases was compared to quantify the amount of wear of piston rings. To quantify the amount of wear of surface of cylinder liners, surface roughness parameters were measured at three positions (TDC, mid stroke, and BDC) on thrust and anti-thrust side. A qualitative analysis was also carried out by surface profiling and Scanning Electron Microscopy (SEM) at same locations.

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