HOME  |  NEWS  |  BLOGS  |  MESSAGES  |  FEATURES  |  VIDEOS  |  WEBINARS  |  INDUSTRIES  |  FOCUS ON FUNDAMENTALS
  |  REGISTER  |  LOGIN  |  HELP
<<  <  Page 2/2
Charles Murray
User Rank
Blogger
Re: Is aluminum strong enough?
Charles Murray   7/13/2012 6:08:21 PM
NO RATINGS
Nice story, Ann. Do you know if these pistons use cast iron cylinder liners? Going way back to the old Chevrolet Vega (does anyone remember the Vega?), engineers have tried to use aluminum. When the Vega's engine had problems, engine builders started employing the cast iron liners. In the '90s, engineers got rid of the cast iron liners and started using hypereutectic aluminum alloys for the blocks and various coatings for the inside of the cylinder, but I don't know how that came out. Are they still using the liners?

Ann R. Thryft
User Rank
Blogger
Re: Is aluminum strong enough?
Ann R. Thryft   7/13/2012 12:45:57 PM
NO RATINGS
Dave, thanks for the feedback on the re-melting process. I agree, it doesn't sound intuitively obvious as a manufacturing process. Regarding the alloy, I'd like to know, too: no details on this product were given. On the company's website appears this general statement about their aluminum pistons. but whether it applies to the new diesel piston is not clear: "We offer aluminum diesel pistons made of Federal-Mogul's exclusive, high-strength B3 alloy (2006) for high-end light-vehicle diesel applications, giving a 10 percent higher fatigue resistance at 440º C to absorb extreme loads in performance engines."

Dave Palmer
User Rank
Platinum
Re: Is aluminum strong enough?
Dave Palmer   7/13/2012 12:19:58 PM
NO RATINGS
Ann, do you know what kind of aluminum Federal Mogul is using for this application? I assume it is an aluminum-silicon alloy.  Do you know if it is hypereutectic, eutectic, or hypoeutectic? (This is metallurgy-speak for more than 12% silicon, about 12% silicon, or less than 12% silicon).

The DuraBowl re-melting process is interesting, and, like many good ideas, seems obvious in retrospect.  Doing failure analysis of aluminum pistons, I've often observed that areas which melted (in service!) are much harder and have a much finer microstructure than the surrounding area.  But I'm not sure that it would have occurred to me to exploit this as a manufacturing process.

Friction stir processing is another way to achieve improved properties in the piston bowl area.  I'm not sure whether anyone is doing this commercially yet, but there is a lot of interest in it.  At last year's Materials Science and Technology conference, Dr. Saumyadeep Jana gave a presentation on friction stir processing of cast aluminum alloys; during the Q&A session, it was clear that just about everyone in the audience (including myself!) had pistons on their mind.  I strongly suspect we'll be seeing friction stir processed pistons in the next couple years.  This would be a good topic for an article.

Ann R. Thryft
User Rank
Blogger
Re: Is aluminum strong enough?
Ann R. Thryft   7/13/2012 11:50:37 AM
NO RATINGS
The aluminum industry has been working on high-strength versions, including alloys such as aluminum-lithium, for some time now. For example, it's the major metal in aircraft, where it's mostly replaced steel (see my upcoming July feature article on aircraft materials). We've also covered a brake rotor prototype made of an aluminum composite:
http://www.designnews.com/author.asp?section_id=1392&doc_id=239090
Aluminum rotors aren't new, but this one is managing to keep up with the increasing heat requirements of today's smaller, hotter engines, not a small feat. There are some under-hood applications of plastics, including carbon composites, such as this one I wrote about
http://www.designnews.com/author.asp?section_id=1392&doc_id=243857
but AFAIK, not yet in car engines.

richnass
User Rank
Blogger
Is aluminum strong enough?
richnass   7/13/2012 10:49:48 AM
NO RATINGS
I'm a little surprised that they found that aluminum is strong enough for this application. And very pleased, asuming it can work well over time. Is plastic next?

<<  <  Page 2/2


Partner Zone
Latest Analysis
The new draw-it-on-a-napkin is the CAD program. As CAD programs become more ubiquitous and easier to use, they have replaced 2D sketching for early concepting.
These free camps are designed for children ages 10 to 18. Attendees are introduced to 3D CAD software and shown how 3D printers can make their work a reality. Here we check out the stops in California and Utah.
A University of Chicago graduate has invented a compact elliptical trainer that lets people work out at their desk while they work.
Dean Kamen told an audience at MD&M East 2014 that FDA regulators aren't to blame for stalling innovation in the medical device industry. Hear what he had to say.
Battery maker LG Chem Power Inc. plans to offer a new cell chemistry that could serve as the foundation for an affordable electric car with a 200-mile driving range by 2017.
More:Blogs|News
Design News Webinar Series
7/23/2014 11:00 a.m. California / 2:00 p.m. New York
7/17/2014 11:00 a.m. California / 2:00 p.m. New York
6/25/2014 11:00 a.m. California / 2:00 p.m. New York
5/13/2014 10:00 a.m. California / 1:00 p.m. New York / 6:00 p.m. London
Quick Poll
The Continuing Education Center offers engineers an entirely new way to get the education they need to formulate next-generation solutions.
Aug 4 - 8, Introduction to Linux Device Drivers
SEMESTERS: 1  |  2  |  3  |  4  |  5  |  6


Focus on Fundamentals consists of 45-minute on-line classes that cover a host of technologies. You learn without leaving the comfort of your desk. All classes are taught by subject-matter experts and all are archived. So if you can't attend live, attend at your convenience.
Next Class: August 12 - 14
Sponsored by igus
Learn More   |   Login   |   Archived Classes
Twitter Feed
Design News Twitter Feed
Like Us on Facebook

Sponsored Content

Technology Marketplace

Copyright © 2014 UBM Canon, A UBM company, All rights reserved. Privacy Policy | Terms of Service