Synapse Synchronic DV - Catastrophic Failure
#1
Synapse Synchronic DV - Catastrophic Failure - Need Your Expert Advice!
Over the July 4 weekend the cast body and pull flange of my Synchronic DV failed catastrophically. I have attached some photos showing a crack in the upper half of the body casting, and the brittle fracture of the pull flange fingers. I would like your help to figure out what happened and why it failed.
I have run the DV for a little over a year in recirculated pull mode, port A only, on my daily driven Mitsubishi Evo 8 at 32 psig boost. This boost level should be well within the design limits and I do not believe it should have failed like this.
Let me know if you have any suggestions.
Flanges exploded off the pull port
Hairline crack in valve body
Brittle failure? Highly crystaline fracture planes
I have run the DV for a little over a year in recirculated pull mode, port A only, on my daily driven Mitsubishi Evo 8 at 32 psig boost. This boost level should be well within the design limits and I do not believe it should have failed like this.
Let me know if you have any suggestions.
Flanges exploded off the pull port
Hairline crack in valve body
Brittle failure? Highly crystaline fracture planes
Last edited by CDrinkH2O; Jul 5, 2016 at 07:43 PM.
#2
EvoM Guru
iTrader: (12)
This is more than likely the fault of the retention rings that come with this diverter valve. I noticed that the notches in the sides of the valve that secure the retention rings for the inlet and output pipes can run a bit too small. I'm sure they do this to allow for a tighter seal, but it puts a lot of pressure on the surrounding metal as it creates a wedging effect on the opposite sides of contact, forcing them apart.
I just bought this valve.
-pal215
I just bought this valve.
-pal215
#3
@pal215
The notches in my valve body are wider than the tabs on the retention ring. (At least they are on my valve body). Since there was plenty of clearance between the tabs and the sides of the notches there was no wedging effect in my case, and so I doubt that this caused the failure. The pressure seal is actually formed by the o-ring between the adaptor pipe and the valve body.
The brittle failure of the edge of valve inlet, and the cracking of the main valve body casting looks like it may have been caused by a spike in internal pressure. I'm pretty sure my 32 psig of boost pressure couldn't cause it to crack like that!
I've logged a ticket with Synapse and will report back on what they say.
The notches in my valve body are wider than the tabs on the retention ring. (At least they are on my valve body). Since there was plenty of clearance between the tabs and the sides of the notches there was no wedging effect in my case, and so I doubt that this caused the failure. The pressure seal is actually formed by the o-ring between the adaptor pipe and the valve body.
The brittle failure of the edge of valve inlet, and the cracking of the main valve body casting looks like it may have been caused by a spike in internal pressure. I'm pretty sure my 32 psig of boost pressure couldn't cause it to crack like that!
I've logged a ticket with Synapse and will report back on what they say.
#4
EvoM Guru
iTrader: (12)
@pal215
The notches in my valve body are wider than the tabs on the retention ring. (At least they are on my valve body). Since there was plenty of clearance between the tabs and the sides of the notches there was no wedging effect in my case, and so I doubt that this caused the failure. The pressure seal is actually formed by the o-ring between the adaptor pipe and the valve body.
The brittle failure of the edge of valve inlet, and the cracking of the main valve body casting looks like it may have been caused by a spike in internal pressure. I'm pretty sure my 32 psig of boost pressure couldn't cause it to crack like that!
I've logged a ticket with Synapse and will report back on what they say.
The notches in my valve body are wider than the tabs on the retention ring. (At least they are on my valve body). Since there was plenty of clearance between the tabs and the sides of the notches there was no wedging effect in my case, and so I doubt that this caused the failure. The pressure seal is actually formed by the o-ring between the adaptor pipe and the valve body.
The brittle failure of the edge of valve inlet, and the cracking of the main valve body casting looks like it may have been caused by a spike in internal pressure. I'm pretty sure my 32 psig of boost pressure couldn't cause it to crack like that!
I've logged a ticket with Synapse and will report back on what they say.
I also feel like these valves could have been made up of a better material, but i'm sure that would be reflected in the cost. I guess time will tell once I start running this valve. It's going to be seeing anywhere from 20 to 40 psi on a weekly basis.
-pal215
#5
Fracture Mechanics Needed!
Even if it was a bad Chinese sand casting, and even if there were some inclusions in the thin wall of the inlet, it would take one hell of an explosive spike in pressure to fracture the inlet wall and valve body like that. I just can't think of what would do that. My FP Green HTA is maxed out at 36 psi.
All I know is that one second I was accelerating at 30 psi of boost, the next there was an explosive pop like an intercooler pipe coming loose, except it was the DV inlet adaptor that got spat off the DV body.
Could bending of the inlet adaptor, caused by the curved rubber pipe feeding it, and multiple boost cycles over a year have caused it to fatigue? I didn't see any polished areas on any of the fracture surfaces so didn't figure it was caused by fatigue.
All I know is that one second I was accelerating at 30 psi of boost, the next there was an explosive pop like an intercooler pipe coming loose, except it was the DV inlet adaptor that got spat off the DV body.
Could bending of the inlet adaptor, caused by the curved rubber pipe feeding it, and multiple boost cycles over a year have caused it to fatigue? I didn't see any polished areas on any of the fracture surfaces so didn't figure it was caused by fatigue.
#6
EvoM Guru
iTrader: (12)
I want to say anything is possible, but realistically these diverter valve manufacturers should account for pipe bend and the side tensions caused by them because no two builds are the same. Over the course of a year or so with many heat cycles there may have been an opportunity to reveal any weak spots in the metal, but for it to just explode like that is unacceptable.
I think Synapse should definitely send you a new unit because you were using it for what it was designed for.
-pal215
I think Synapse should definitely send you a new unit because you were using it for what it was designed for.
-pal215
#7
EvoM Guru
iTrader: (1)
Synapse will prob send you a new one. I broke one like that trying to install it and they sent me a new one. Makes me hesitant to put the one I have on my car now.
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#8
Synapse are going to send me a new body. They said the problem was probably caused by a crack in the body casting - a manufacturing defect. They also mentioned that they will have a revised version of the body available in a weeks time, which should prevent this problem in future.
#10
Evolving Member
iTrader: (12)
Synapse are going to send me a new body. They said the problem was probably caused by a crack in the body casting - a manufacturing defect. They also mentioned that they will have a revised version of the body available in a weeks time, which should prevent this problem in future.
#11
EvoM Guru
iTrader: (1)
Originally Posted by cdrinkh2o
What are you now using instead of the Synchronic?
The following users liked this post:
CDrinkH2O (Jul 13, 2016)
#12
I love the rapid activation of the Synchronic in pull mode during hard acceleration, and the complete lack of flutter in transition from vac to boost. I'm interested how the Tial QRJ compares.
#13
EvoM Guru
iTrader: (1)
Thanks for the tip. Are you running the Tial QRJ in full recirc with 1.25" hoses in/out? If so how does the performance compare to the Synapse Synchronic DV?
I love the rapid activation of the Synchronic in pull mode during hard acceleration, and the complete lack of flutter in transition from vac to boost. I'm interested how the Tial QRJ compares.
I love the rapid activation of the Synchronic in pull mode during hard acceleration, and the complete lack of flutter in transition from vac to boost. I'm interested how the Tial QRJ compares.