Federal-Mogul Powertrain said it was supplying pistons, pins and ring packs for the quad-turbo diesel engine that will power the 2017 BMW 750d and 750Ld xDrive models.
The new three-litre engine, the world's most powerful six-cylinder diesel, develops 294 kW/400 hp and peak torque of 760 Nm/560 lb-ft.
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Tasked with delivering low levels of blow-by and oil consumption over the entire life of the vehicle, the supplier's piston and ring engineers worked closely with BMW engineers throughout the development program. The high level of co-operation enabled the engine to incorporate a number of advanced technologies.
"Meeting the requirements for this engine was very demanding," said Gian Maria Olivetti, chief technology officer, Federal-Mogul Powertrain. "Having four turbochargers tends to increase blow-by, which is also influenced by the use of direct bore coating rather than cylinder liners, resulting in slightly greater thermal expansion. Additionally, the higher peak cylinder pressures and specific power mean that the loads on both piston and ring pack are increased."
The supplier met all the targets by combining a number of technologies with a product traceability system. The aluminium piston uses DuraBowl remelting to refine the micro-structure of the bowl rim and increase its strength and advanced 2D ultrasonic inspection ensures zero defects. A high cooling gallery location reduces bowl rim stresses through optimum cooling and an EcoTough skirt coating reduces friction and wear, improving scuff resistance.
The ring pack was developed with the support of 3D simulation software to meet the stringent blow-by and oil consumption targets and incorporates a number of technologies that are proprietary to Federal-Mogul Powertrain. The first compression ring carries a Goetze Diamond Coating (GDC) to optimise friction and wear; the oil control ring uses the LKZ profile, which actively pulls oil away from the combustion chamber for low oil consumption throughout the life of the engine.
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By GlobalDataThe traceability of every individual compression ring, rather than just each batch, is ensured by using DMC (data matrix codes) to record function-related features following 100% inspection, giving complete control of the entire production.
In addition to the pistons, pins and ring packs, Federal-Mogul Powertrain also supplies bearings, valves, valve cotters and spring retainer caps for this engine.
