Federal-Mogul Powertrain says it has developed a new diesel piston aluminium alloy, known as DuraForm-G91.

The supplier maintains in benchmarking tests, the new alloy provides between three and five times the component life of established as-cast materials in highly loaded, diesel engines.
The increased strength of the new material also supports higher mechanical loads, allowing engines to operate at higher specific power and more efficiently.

The alloy properties facilitate piston designs with a lower compression height and reduced mass. The resulting benefits of less reciprocating mass and smaller, lighter cylinder blocks contribute to vehicle CO2 emissions reduction.

“This is an example of the enabling technologies developed by Federal-Mogul Powertrain that help our customers to make each new engine generation more compact, lighter and with a smaller carbon footprint than its predecessor,” said Federal-Mogul Powertrain CTO, Gian Maria Olivetti.

“With our materials scientists…we are committed to developing new concepts for both aluminium and steel-based pistons for diesel vehicles, offering…solutions for the various needs of our customers.”

DuraForm-G91’s composition delivers increased fatigue strength, particularly in the high temperature range typically associated with highly loaded diesel pistons.

DuraForm-G91 has been developed using testing techniques that shorten the validation period to production readiness.

“We have employed specially designed accelerated base engine tests combined with ‘engine-like’ rig testing procedures,” said Federal-Mogul Powertrain Material Development and Characterisation, Global Pistons, Roman Morgenstern.

“Engine-like rig testing combines thermomechanical fatigue (TMF) with high cycle mechanical fatigue (HCMF), which directly reflects the fatigue-critical load conditions seen by automotive diesel pistons in the engine.”