Düsseldorf, 20-06-08 

Cast Metals for Engine Components are Heavy-duty Specialists

The stresses acting on reciprocating engines and, by the same token, on cylinder crankcases and cylinder heads are growing continuously. This is mainly due to the fact that the power output per litre as well as combustion pressures and temperatures keep going up while power-to-weight ratios are declining. In the last few years, this resulted in a variety of new developments not only in manufacturing technology and design but also in the selection of materials. For a long time, cylinder crankcases that met all demands could be made from cast iron with lamellar graphite (GJL). Now that strength requirements keep increasing, however, more and more thin-walled castings made of GJL-250 as well as more sophisticated alloys such as GJL-270 plus and high-strength GJV-450 and GJS-600 are being used to an ever-growing extent. For even lighter constructions, AlSi or AlCu alloys have found their way into this cast iron-dominated sector although, unlike cast iron, piston bearing surfaces made of these materials demand special treatment. However, solutions to this problem have been found, and magnesium, an even lighter material, is being used in the field here and there.

The production of cylinder heads is dominated even now by special aluminium alloys whose castability, density, heat conductivity, and machinability has been developed far enough for practical application.  

A publication in two parts describes and comments on the current status and development trends in the use of materials for modern engine cylinder crankcases and cylinder heads. The publication is available free of charge from ZGV – Zentrale für Gussverwendung, Sohnstraße 70, D-40237 Düsseldorf. (zgv@bdguss.de) 

 

The subjects dealt with in previous ZGV information brochures include

• Bionically Designed Castings with a Great Lightweight and Strength Potential
• Precision Casting – an Economical Solution for Complex Components  
• Austenitic Cast Iron Features Properties for Extreme Applications
• Welding of Castings – an Overview
• High-tech Castings Mirror the Dynamic Development of Wind Power Generation
• Cast Iron with Lamellar Graphite – still the most Frequently Used Cast Iron Material
• Cast Cylinder Heads and Crankcases Offer Versatile Solutions for the Cars of Today and Tomorrow
• High-alloy Casting Materials for Special Applications in the Pump Industry World
• Steel Castings for Buildings all over the World
• What to know about Cast iron with spheroidal graphite
• Versatile Non-destructive Tests for Castings
• Black Malleable Cast Iron – Strong and Tough