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An Approach of the Engine Cylinder Block Material
Abstract
The increasing demand for energy savings in cars of high production volume, especially those classified as emerging market vehicles, has led the automotive industry to focus on several strategies to achieve higher efficiency levels from their systems and components. One of the most diffuse initiatives is reducing weight through the application of the so-called light alloys. An engine cylinder block can contribute nearly two percent of the vehicle's total mass. Special attention and soon repercussion are given when someone decides to apply a light alloy such as the aluminum to this component. Nonetheless, it is known that peculiarities in terms of physical, chemical and mechanical properties, due to the material nature, associated with regional market characteristics make the initial feasibility analysis study definitely one of the most important stages for the material choice decision. The present review study will address the technical aspects related to the issue of material selection of the four cylinder block engine most commonly used in emerging markets, where cost and fuel efficiency is a primordial need. In addition, a contribution attempt for the understanding on the correlation of cost impacts with the benefits of improved efficiency.
... The automotive industry, characterized by its rigorous quality standards and competitive nature, continuously seeks methods to enhance production efficiency and product quality. A critical component in automotive manufacturing is the cylinder block, a central part of an engine's structure (Filho, 2013). The production of cylinder blocks involves complex casting processes, where defects can significantly impact the overall quality and performance of the final product. ...
The implementation of Six Sigma methodology has demonstrated significant effectiveness in enhancing quality and reducing defects in manufacturing processes. This study examines the application of Six Sigma principles to minimize defects in automotive cylinder block production. Employing the Define, Measure, Analyze, Improve, and Control (DMAIC) framework, the research identifies critical factors contributing to defects and implements strategic improvements to address quality issues. The Define phase established key elements related to quality products, including processes, suppliers, customers, and their requirements, utilizing SIPOC diagrams and Critical to Quality (CTQ) factors. In the Measure phase, data collection focused on determining process baselines and root causes, employing Defects Per Million Opportunities (DPMO) and Control Charts. Analysis revealed a DPMO value of 4,987 with a sigma level of 4.077σ. The Analyze phase identified causes of production process failures, with "Sunakui" (sand hole) emerging as the predominant defect type in cylinder block production. The study concluded that unsuitable sand composition was the root cause leading to defects. To address this issue, the research recommends implementing a Poka-Yoke system with an integrated alarm to monitor and ensure appropriate sand composition, thereby enhancing overall product quality.
... The engine block provides the support for the other engine component parts. The engine block is made of cast aluminum cylinder material with cast iron lines and piston having a prevail over simple cast process in which the piston runs directly on the alloy bores for diesel engine (Filho, 2013, Ansari 2020. The needs to manufacture engine blocks that achieves fuel consumption reduction in locomotive engine has resulted in shift from cast iron to aluminum alloy as aluminum light engine block lead to enhanced thermal conductivity and efficiency (European aluminum association, 2011, Torres et al 2006) Thermal conductivity arose from low temperature of the crankshaft; bearing and inner bore region in the morning on start of the engine and on engine running that can reach up to 1500c and 2000c respectively, but dissipate its heat in to coolant (European aluminum association, 2011). ...
Transportation through the Railway is more appreciative compared to the road transport. Many people have lost their lives and properties through the road transportation, hence the researcher tried to look into the problem of the road transport in Nigeria. In the western word the train is more popular compared to the use of vehicles to convey human beings and goods. The road traffic accident statistic from 1990 – 2012 was recorded in 2013, by the road safety commission. The researcher used the descriptive survey research design to carry out this study. The data was illustrated using histogram to demonstrate the rate of accident on Nigerian road showing fatal, serious, minor, killed and injured. Solutions were provided by the researcher on how to overcome the problem on Nigeria road. By providing rail way transport, because rail way transport has no records of accident.
... Engine block provides the support for the other engine component parts. Cast aluminum cylinder with cast iron liners and piston have prevailed over simple cast process in which the piston runs directly on the alloy bores for diesel engine [35,36]. The needs to manufacture engine blocks that achieves fuel consumption reduction in LE has resulted in shift from cast iron to aluminum alloy as aluminum lighter engine block leads to enhanced thermal conductivity and efficiency [37,38]. ...
This work presents the review of locomotives and the future of railway automotive power in Africa. Locomotives down time on account of inadequate spare parts still remains a challenge in African. It is thus, imperative to review the locomotives in African, to establish the current capabilities as well as provide recommendations to bridge the gaps and its extrapolated trends in future. Firstly, the comparison factors were track length, electrified rails, number of locomotives and yearly passengers on each of Egypt, Ghana, Kenya, Nigeria, South Africa and Zambia rails. Secondly, the focus was on engine parameters from literatures and maintenance logbooks of locomotives. From available data, it was found that South Africa and Egypt have more advanced rail system than the rest four selected countries. It was also found that additive manufacturing, 3D printing, ductile cast iron and die-forging can be used to produce the engine body for diesel engine using steel and aluminum alloys while aluminum silicon and tin doped with copper are good for reciprocation mechanisms. And finally, increased reliability of locomotives can be guided by an engine selection matrix, while use of renewable and energy hybridization are needed to meet the expansion of railroads in Africa.
div class="section abstract"> Light weight technologies are inevitable in the automotive industry to increase fuel efficiency and meet emission norms. An engine cylinder block is one of the major elements contributing approximately 3-4 % of the automobile weight. Aluminum cylinder block with cast-in liner is almost 40-55 % lighter than a conventional cast iron block [ 1 ] and hence the manufacturing processes and challenges associated with them are of high interest. A heterogeneous cast-in liner of gray cast iron in cast aluminum offers a low cost option, but the mechanical bond created between the liner and aluminum interface is prone to gap formation which affects the engine in terms of in-effective heat transfer, distortion and higher blow-by, and thereby high oil consumption & higher emissions. This study aims at reducing this interface bonding gap by in-depth study of critical process parameters involved in manufacturing of cylinder blocks.
The study involved a single cylinder petrol engine block manufactured using High Pressure Die Casting (HPDC) process. Using detailed cause and effect analysis, various stages of HPDC like die design, including gating & cooling system were studied & improved using mold flow analysis. Die casting process parameters like die temperature, warm up shots, and biscuit thickness were optimized. Evaluation of bonding gap was carried out using non- destructive techniques like Immersion Ultrasonic Testing & Computed Tomography Testing and a comparative analysis with experimental results of both methods are discussed. Considering initial investment, testing cost, testing time, sensitivity & resolution, a feasible method may be selected for implementation.
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div class="section abstract"> The global automotive industry is growing rapidly in recent years and the market competition has increased drastically. There is a high demand for passenger car segment vehicles with high torque delivery and fuel economy for a pleasant drivability experience. Also, to meet the more stringent emission requirements, automakers are trying very hard to reduce the overall vehicle gross weight. In lowering both fuel consumption and CO2 generation, serious efforts have been made to reduce the overall engine weight. An engine cylinder block is generally considered to be the heaviest part within a complete engine and block alone accounts for 3-4% of the total weight of the average vehicle, thus playing a key role in weight reduction consideration. Aluminum casting alloys as a substitute for the traditional cast iron can mean a reduction in engine block weight between 40 and 55% [ 9 ], even if the lower strength of aluminum compared to grey cast iron is considered. Thus, designers of aluminum engine blocks are constantly striving to design better and lighter blocks in order to improve and enhance the efficiency of automobile engines.
This work is a part of design and development of 2.2 L, 4-cylinder turbocharged intercooler (TCIC) diesel engine for a complete new monocoque vehicle platform, focused on automotive passenger car application with high operating in cylinder combustion pressures around 190 bar. The paper portrays the effective system approach essential for selecting aluminum as the choice of material, selection of alloy composition, casting process, heat treatment and key design criteria. The ongoing substitution of cast iron in engine blocks by aluminum casting alloys also requires the design and development of a new “tribological” system. Selection of cost-effective cylinder liner system and the drawbacks of this heterogeneous concept such as the lack of metallic bonding with the surrounding cast aluminum alloy and higher bore distortion are addressed during design and development. Statistical database, quality tools like design failure mode and effect analysis (DFMEA), design for manufacture and assembly (DFMA) etc., classical design methods, finite element analysis (FEA), advanced computer-aided engineering (CAE) and computational fluid dynamics (CFD) simulation tools have helped in materializing this concept into production. Experimental validation of the design is carried out as a part of design verification and validation. And results are elaborated to show the effectiveness of integrated approach used for the development program.
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The engine block is one of the important components in a motorcycle. It plays an important role in ensuring that the motorcycle works properly. The surface roughness of the engine cylinder affects the engine efficiency. Therefore, researchers underwent experiments to find out the goodness of the surface for the engine block. Through the surface roughness test machine and cutting using a CNC milling machine, it shows that the cutting speed and speed rate affect the surface roughness results. Response surface methodology (RSM) and Minitab methods are used to obtain statistical analysis data in completing this project.
Volume 18 addresses friction and wear from a systems perspective, while providing a detailed understanding of why it occurs and how to control it. It explains the basic theory of friction and wear, and offers valuable insight on the forces, mechanisms, and interactions that are involved. It examines common wear scenarios, including wear by particles or fluids, rolling-contact wear, sliding wear, impact wear, and both chemical and environmentally assisted wear. It also covers operational wear, addressing several cases, including tool and die wear, bearing wear, engine wear, turbine wear, pump wear, and seal wear. In addition, the volume provides information on lubricants and lubrication, coatings, surface treatments and modifications, and the tribology of irons and steels, cobalt-base alloys, titanium, aluminum alloys and composites, cemented carbides, ceramics, polymers, and polymer composites. It also introduces the topic of condition monitoring, addressing wear particle analysis, vibroacoustic monitoring, and motor current signature analysis. For information on the print version of Volume 18, ISBN 978-1-62708-141-2, follow this link.
In the present study, a novel technique to replace conventional honing with a laser hatch patterning accompanied by nitriding called Pulsed Laser Hatch patterning and Nitriding (PLHN) process has been identified and reported in detail. Effect of process parameters like laser wavelength (532 nm and 1064 nm) and N2 gas flow rate (5 – 35 L/min.) on the nitride layer quality, average roughness, hardness, and elevated temperature tribological performance of A356 cast Al alloy has been investigated. The formation of a thin AlN layer was confirmed from (GIXRD and XPS) analysis. The crack-free nitride layer was produced with a maximum thickness of 13.48 ± 0.53 µm, and 11.35 ± 0.34 µm using laser wavelengths 532 nm (at 15 L/min.) and 1064 nm (at 25 L/min.) respectively. At these optimized process parameters, the PLHN specimen processed at 532 nm and 1064 nm laser wavelengths showed a maximum of 212.57% and 144.73% increment hardness values as compared to the base material (1.52 Gpa). While the wear rate (200˚C) was reduced by 43.25% and 36.48% for the PLHN specimen processed at 532 nm and 1064 nm respectively in comparison with the base material.
Aluminium engine blocks require the use of grey iron liners to resist wear from sealings mounted in pistons. Liners can be inserted into the piece after machining or can be cast-into the block. The latter method allows for higher productivity, but has the disadvantage to promote the development of residual stresses in critical areas such as the cylinder bridges. These stresses arise from the differences in the thermal expansion coefficient of iron and aluminium and, if high enough, may promote the failure of the block. This work describes the procedure followed to measure the residual stresses that develop in the cylinder bridges in type A319 aluminium–silicon–copper engine blocks with cast-in grey iron liners. The measurements were obtained by extensometric means. It was found that the stresses can be higher than 150MPa in tension, depending on the geometry and size of the piece. It is concluded that these types of analyses provide for an early advice when changes take place in design, processing or material.
Volume 1 addresses the selection and application of ferrous metals and alloys, including cast irons, carbon and low-alloy steels, tool steels, stainless steels, and nickel and cobalt-base superalloys. As the lead volume in the Handbook series, it lays the groundwork for understanding the hierarchical nature of metals and how to leverage the underlying process, structure, property, performance relationships that define them. The volume draws on the knowledge and insight of more than 200 experts with experience in materials-centric product design, manufacturing, and quality control. It contains more than 1,300 illustrations (photographs, charts, and graphs) and over 500 tables filled with alloy designation, composition, and mechanical and physical property data. For information on the print version of Volume 1, ISBN 978-0-87170-377-4, follow this link.
Clay-like sediments composed mainly of alumina and iron oxide and practically devoid of silica were first described by Berthier in 1821 from Les Baux, in south-east France; such sediments were later named "bauxite' from their type locality. The term bauxite is now used for lithified or unlithified, residual weathering products rich in alumina and low in alkalis, alkaline earth and silica. From an industrial perspective, bauxite is a natural material that can be economically processed to high-purity alumina in the Bayer Process, thus making bauxite the principal ore of aluminium. Bauxite consists primarily of a mixture of aluminium hydroxides. Gibbsite, boehmite and, to a lesser extent, diaspore are the main aluminous minerals. The stratigraphic and geographic distribution of bauxite is described. -from Authors
Various coatings, especially nickel based ceramic composite (NCC) coatings, have been considered as an alternative to the use of iron plating on aluminum pistons in aluminum cylinder bore engines. Laboratory simulation tests were conducted to determine the scuffing and wear behavior of piston coatings against 390 Al engine cylinder bore. The tested piston coatings included nickel–tungsten (Ni–W) plating, electroless Ni plating, Ni–P coatings with ceramic particles such as boron nitride (BN), SiC, or Si3N4, as well as titanium nitride physical vapor deposition (PVD) coating, diamond-like carbon (DLC) coating, and hard anodizing. The scuffing and wear resistances of these coatings were evaluated and compared with tin plating and iron plating. Wear tests were performed in lubricated sliding at 400 K, using a modified Cameron Plint High Frequency test machine with a special fixture to hold the piston samples. Scuffing tests were conducted under the conditions in which lubricant starvation occurred. Metallographical work and chemical analysis of the interactive surface layers were performed on the tested samples. The simulation test results ranked the relative performance of the coatings against 390 Al bore, and revealed their tribological characteristics. Ni–P–BN coating, iron plating and Ni–W plating showed very good scuffing resistance when sliding against 390 Al bore samples. DLC, electroless Ni plating and Ni–P–SiC coating had moderate scuffing resistance against 390 Al. Ni–P–Si3N4 and TiN coatings had marginal scuffing resistance against 390 Al. TiN PVD coating had the most severe wear on 390 Al bore samples. Hard anodizing, DLC, Ni–P–SiC and Ni–Si3N4 coatings had less severe wear on 390 Al than TiN coating. With very good wear resistance themselves, Ni–W plating, electroless Ni plating, iron plating and Ni–P–BN coating produced the least wear on 390 Al. Engine dynamometer tests were conducted to confirm the simulation test results. This work indicates that the scuffing and wear bench simulation tests can be used as a rapid, low-cost and repeatable means of screening and studying the tribological behavior of the potential material combinations of piston coatings and cylinder bores.
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