Thermo-Tribological Degradation and Lubrication Collapse in a High-Mileage Gasoline Engine: A Real-Engine Case Study

Thermal overload in internal combustion engines may progressively destabilize lubricant-film integrity and promote severe tribological deterioration within highly stressed contact interfaces. This study investigates the thermo-tribological degradation sequence of a high-mileage gasoline engine subjected to prolonged idle operation under impaired cooling conditions, ultimately resulting in engine seizure. The investigated engine had accumulated 356,724 km, while the lubricant had remained in service for approximately 26,724 km prior to the experiment. The post-failure investigation combined teardown inspection, geometrical camshaft assessment, reverse gravimetric reconstruction, hydraulic tappet surface profiling, XRF surface characterization, laboratory oil analysis, and SEM/EDS evaluation of wear debris. The results demonstrated strongly localized degradation concentrated primarily within the cam–tappet interfaces. Severe non-uniform camshaft wear was accompanied by pronounced hydraulic tappet surface damage and evidence of unstable boundary-lubrication conditions. Laboratory oil analysis revealed elevated wear-metal concentrations, depletion of the alkaline reserve, increased oxidation indicators, and a final Class D oil condition assessment. SEM/EDS characterization identified Fe-bearing wear debris associated with sustained material removal and debris recirculation during the final degradation stage. The combined evidence supports a coupled thermo-tribological degradation mechanism involving lubricant deterioration, boundary-lubrication instability, adhesive wear acceleration, oxidative surface degradation, and debris-assisted surface damage preceding final engine seizure. The present case study provides experimentally documented evidence of lubrication collapse under real-engine thermal runaway conditions and highlights the critical role of lubricant condition in maintaining tribological stability under severe thermal loading.