|Thursday, 17 May 2012, 23:05 HKT|
|Hybrid Liner design helps meet new challenges of downsized diesel and gasoline engines|
Friedberg, Germany, May 17, 2012 - (ACN Newswire) - Federal-Mogul Corporation (NASDAQ: FDML) is increasingly using a dual-material cylinder liner technology to reduce bore distortion and improve function in the latest generation of lighter, highly-loaded gasoline engines. The company's patented Hybrid Liner technology provides reliable, cost-effective, long-term performance while reducing engine oil consumption, especially in high-output aluminium engines with small interbore bridges and weight optimized designs.
"Federal-Mogul is helping engine manufacturers to increase the power output and durability of smaller engines, supporting them in a key area of their global CO2 reduction strategies," said Gian Maria Olivetti, Federal-Mogul's vice president for Technology and Innovation, Powertrain Energy. "Cylinder bore distortion is one of the main factors limiting increases in power and torque outputs, particularly in lightweight aluminium cylinder blocks. Our patented Hybrid Liner increases the strength and stiffness of the combined block and liner assembly, allowing significant weight reduction without compromising engine performance and durability."
Federal-Mogul's Hybrid Liner integrates the liner into the aluminium block casting more effectively than alternative technologies, both structurally and thermally. It comprises a conventional cast iron sleeve with an aluminium coating applied to the exterior through a proprietary process. The cast iron sleeve provides good tribological properties and is compatible with cost-effective ring packs.
The outer surface of the liner is manufactured to provide a surface topography that is conducive to mechanical interlocking with the aluminium block material. The liner coating is an AlSi12 alloy with a melting point below that of the aluminium engine block, which provides outstanding intermetallic bonding between the surfaces of the two materials. To meet the cost and robustness requirements of series production, the coating is applied in a process that uses advanced wire arc thermal spray technology to ensure that coverage, thickness and bonding strength are uniform around the complete height and circumference of each liner. The coating surface roughness is also controlled, to provide undercuts and micro-porosities so that an extremely strong, intermetallic transition zone is formed between the coating and the block casting material.
"Compared to alternative technologies, the Hybrid Liner reduces bore distortion in a running engine by two-thirds," said Olivetti. "Maximum second order bore distortion can be as low as 11 percent of that experienced by corresponding cast-in liners, while the cylindrical distortion under operating loads is up to three times better. As a result, oil consumption is reduced by up to 40 percent."
Federal-Mogul's Hybrid Liner also results in up to 30 percent higher heat transfer rates, reducing the cylinder wall temperature by up to 40 degrees Celsius (104 degrees Fahrenheit) compared to alternative designs. Dynamic strength increases as well; in a cyclic pulsing pressure test, the Hybrid Liner showed no failure at pressures of up to 200 bar, whereas a standard liner block design cracked at 100 bar.
"Federal-Mogul's Hybrid Liner also allows engine manufacturers to improve packaging by reducing the distance between adjacent cylinders; pressure die-cast engine blocks with Hybrid Liners can have a material wall thickness of just 3mm between the bores," Olivetti added. "If a water channel is drilled between two cylinders, the Hybrid Liner technology limits the formation of cracks, allowing coolant to penetrate only as far as the liner coating. Conventional liners can allow water to seep down the joint between liner and casting, reaching the crankcase and contaminating the lubricating oil."
Federal-Mogul's Hybrid Liner is produced at its Powertrain Energy manufacturing facility in Friedberg, Germany. The technology was a finalist in the 2012 Automotive News PACE Awards.
Federal-Mogul Corporation is a leading global supplier of powertrain and safety technology and innovation to improve fuel economy, reduce emissions and enhance vehicle safety. The company serves the world's foremost original equipment manufacturers of automotive, light, medium-, heavy-duty, aerospace, marine, rail and off-road vehicles; and industrial, agricultural and power-generation equipment; as well as providing well-known brands in the global aftermarket. Federal-Mogul's world-class global engineering, lean manufacturing and distribution network deliver best-in-class quality products and services at competitive cost. The company's sustainable global profitable growth strategy creates value and satisfaction for its customers, shareholders and employees. Federal-Mogul was founded in Detroit in 1899. The company is headquartered in Southfield, Michigan, United States and employs 45,000 people in 34 countries. The company's website is www.federalmogul.com .
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Copyright (c) Thomson Reuters 2012. All rights reserved.
May 17, 2012
Topic: Press release summary
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