AAM – Applications – 1 Power train Contents 1 Power train........................................................................................................................ 3 What to see in this section............................................................................................ 3 1.1 Engine ...................................................................................................................... 4 Aluminium engines ....................................................................................................... 4 1.1.1 Piston ................................................................................................................... 6 Pistons for gasoline and Diesel engines ...................................................................... 6 Operating conditions..................................................................................................... 7 Piston materials ............................................................................................................ 9 Design considerations for automotive pistons............................................................ 12 1.1.2 Cylinder block .................................................................................................... 14 Introduction................................................................................................................. 14 Requirements for aluminium cylinder blocks.............................................................. 15 Competition between aluminium and grey iron .......................................................... 16 Design features .......................................................................................................... 17 Block design variants.................................................................................................. 18 Bolting concepts ......................................................................................................... 20 Open- and Closed-Deck concepts ............................................................................. 21 Pre-cast features and add-on parts............................................................................ 22 Cast-in inserts............................................................................................................. 24 Criteria for alloy selection ........................................................................................... 25 Alloys: Composition and heat treatment..................................................................... 26 Applicable casting processes ..................................................................................... 27 Example: Ford Zetec SE – CPS® Process ................................................................ 28 Example: PSA 2.0L HPI (HPDC)................................................................................ 29 Example: Lupo Block 1.2L.......................................................................................... 30 1.1.3 Cylinder linings................................................................................................... 31 Introduction................................................................................................................. 31 Requirements ............................................................................................................. 33 Technologies – Overview ........................................................................................... 34 Comparison of liner technologies ............................................................................... 35 Liner solution: Heterogeneous concept Grey iron cast-in .......................................... 36 Liner solution: Monolithic concept (ALUSIL®)............................................................. 38 Liner solution: Quasi-Monolithic concept LOKASIL®.................................................. 39 Liner solution: Heterogeneous concept SILITEC® ..................................................... 41 Liner solution: Heterogeneous concept HYBRID, GOEDEL® ................................... 43 Liner solution: Quasi-Monolithic Concept TRIBOSIL®............................................... 44 Other liner solutions.................................................................................................... 46 Cylinder surface treatment – Honing of hypereutectic AlSi surfaces ......................... 48 1.1.4 Cylinder head..................................................................................................... 49 Introduction................................................................................................................. 49 Requirements – Thermal conductivity vs. strength .................................................... 50 Requirements for aluminium cylinder heads – High- and low-cycle fatigue............... 51 Design features .......................................................................................................... 52 Criteria for alloy selection ........................................................................................... 54 Alloy composition and heat treatment ........................................................................ 55 Applicable casting processes ..................................................................................... 56 Example: PSA 2.0L HDI – Gravity Die Casting.......................................................... 57 Example: BMW 2.0L DI – Gravity Die Casting........................................................... 58 Example: BMW 2,0l 4-Cylinder – Rotacast®.............................................................. 59 Example: Isuzu Diesel – Rotacast® ........................................................................... 60 1.2 Fuel system............................................................................................................ 61 Aluminium helps to meet targets of HC-emission laws .............................................. 61 Future fuel systems need new materials technologies .............................................. 62 1.2.1 Fuel filler pipe..................................................................................................... 63 Product description..................................................................................................... 63 Example: Volvo V70/S80/S60/XC90 Fuel Filler Pipe ................................................. 64 Example: Porsche 911/Boxster Fuel Filler Pipe......................................................... 65 1 1.2.2 Fuel tank ............................................................................................................ 66 Technical requirements .............................................................................................. 66 Technical feasibility .................................................................................................... 68 Prototype production .................................................................................................. 70 1.3 Liquid lines ............................................................................................................. 71 Aluminium tubing and connections............................................................................. 71 1.3.1 Applications........................................................................................................ 72 Application requirements............................................................................................ 72 Tube materials for liquid lines..................................................................................... 73 1.3.2 Connections ....................................................................................................... 74 Screw Connections – Fittings..................................................................................... 74 Hose-to-tube connection ............................................................................................ 76 Special connections – Magnetic pulse forming .......................................................... 77 Quick connectors........................................................................................................ 78 Connections by flame brazing .................................................................................... 79 Connections by flame brazing – Materials ................................................................. 80 1.3.3 Burst pressure.................................................................................................... 81 Burst pressure of liquid lines ...................................................................................... 81 1.3.4 Bending.............................................................................................................. 82 Bending of liquid lines................................................................................................. 82 1.3.5 Corrosion ........................................................................................................... 83 Corrosion Resistance – Long Life Materials............................................................... 83 1.4 Heat shields............................................................................................................ 84 Use of Aluminium Heat Shields.................................................................................. 84 Application Areas.......................................................................................................