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The recent trends in diesel engines are discussed, and also the consequences in materials selection for engine cylinder blocks. The increasing demand for higher specific power and the need for weight reduction and decrease of emissions require the use of stronger materials for cylinder blocks, opening a promising space for compacted graphite iron (CGI). The properties of CGI are described, in particular those required for engine cylinder blocks (fatigue strength and elastic modulus). The introduction of high-pressure common-rail technology in 1997 marked a significant turning point in European sales of diesel-fueled vehicles (Buchholz, 2003). Aluminum alloys will hardly endure the high pressure numbers mentioned above for cylinder blocks (Martin et all, 2003). Some studies from AVL set limits of 170 bar (for inline engines) and 150 bar (for V engines) for aluminum in diesel engine cylinder blocks. Engine blocks design concepts - for cast iron - were developed focusing the local loads acting on each block region (Figure 4 – Vollrath, 2003), and exploiting the mechanical properties of the material. The use of these concepts allows considerable block weight reduction. For instance, for a turbocharged 2,0 L diesel engine, the block weight was reduced from 42,8 kg to 29,5 kg. For a turbocharged gasoline engine, the block weight was reduced from 38,5kg to 28,5 kg (Vollrath, 2003). CGI also shows a higher elastic modulus, when compared to gray iron. The results in Figure 10 were obtained from two sources: test bars and main bearings of a 12.0L cylinder block.
Tags : compacted graphite iron, aluminum alloys, main bearings, fatigue strength, cylinder blocks, gasoline engine, engine cylinder, rail technology, gray iron, iron content, cylinder block, specific power, engine blocks, materials selection, weight reduction
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