PowerPoint Presentation

Magnesium Alloy and Composite I.C. EnginesAriff Mohammed Tajdeen A1Conventional engine materials Aluminium and Cast IronProperties of Aluminium

PropertiesDensity of solid2700 kg m3Young's modulus 70 GPaRigidity modulus 26 GPaPoisson's ratio 0.35Thermal conductivity235 W m1 K1 Melting point933.47 K [660.32 C]2Need Of the hour334

What about composites?

5aj62Found and patented by Noranda Aluminium Holding corp. die castable alloy of magnesium that have good creep resistance at high temperature. They contains magnesium, aluminum, and strontium.In the name the 'J' refers to Strontium.

6Alloy MgAl% Sr%Mn %AJ 62Balance620.34Magnesiumm alloy properties

7

8AJ62 was chosen for its unique attributes of thermal and mechanical strength,casting and corrosion behavior, and superior creep resistance.8Problems with Aj62 easily corroded when in contact with water Recycling Mg-alloys need special processesSpecialized plants/equipment needed for manufacturing

9the bmw n52 engine series!

10

Manufacture BMW uses a special high pressure die casting (HPDC) method to cast Mg engine blocks.Problem of water corrosion is solved by having Aluminium inserts and cylinder liners over which coolant water flows.engineers met the challenge of balancing magnesium and aluminums different coefficients of specific thermal expansion, which required a breakthrough level of casting technology and process reproducibility. As the magnesium housing shrinks around the aluminum insert, the thermally complex casting process ensures that both components heat up and cool down at precisely the right time during production.11

12

ManufactureThe two-piece mold, weighing nearly 60 tons, closes over the aluminum insert with 4,000 tons of hydraulic force. Liquid magnesium alloy (at 700C) is then poured into the mold, maintaining a 970 bar pressure within the cavities and solidifying within ten seconds. After 20 seconds cooling time the metals are firmly bonded and the crankcase is robotically removed. Next the crankcase undergoes heat treatment, and further machining and finishing processes are completed.13

ManufactureThe engine bedplates magnesium construction results in much higher torsional stiffness, providing greater fatigue strength, which supports the R6s top speed of 7,000 rpm.

Alusil is coated on inner surface of Aluminium inserts14

POIMagnesium alloy engine was produced in 300,000 BMW vehicles in 2006Magnesium alloy crankcase is 24 percent lighter than conventional aluminum engineR6 is lightest 3.0 liter inline six-cylinder gasoline engine in the world at 161 KgHollow camshafts are used.Another cause for success of the N52 series is the use of BMWs valvetronic lift system.

15

So can we make it lighter?16What about composites?

17Can you make an engine out of plastic?18Why not !?When do you think the first plastic engine was made ?Meet matti holtzberg

1979 founded polimotor Currently president of Composite Castings Has 17 patents regarding composite engine block manufacture Inactive on LinkedIn and Facebook 191969Matti Holtzberg read an article in a technical magazine at the Hackensack, New Jersey, public library espousing a new plastic allegedly tough enough to withstand the harsh conditions existing inside car engines. Holtzberg obtained a sample of the French material, which he used to make an experimental piston. After 20 minutes of operation inside an Austin Mini engine, combustion heat burned a hole through his first plastic pistons crown.1970sHoltzberg made and sold ultralight plastic pistonsnow topped with aluminum crownsfor racing use.1979Holtzberg founded Polimotor (shorthand for polymer motor) to develop the worlds first plastic-intensive engine.1980After Holtzbergs first engine ran,Automotive Industriesmagazine featured it in a cover story.1982By the timePopular Sciencechimed in, Holtzbergs second-generation Polimotor produced 300 hp and weighed 152 pounds compared to 88 hp and 415 pounds for a contemporary Ford Pinto engine.19841985A Lola sports car powered by a Polimotor and backed by Amoco Chemical ran a half-dozen IMSA Camel Light road races with a best finish of third at Lime Rock. One broken connecting rod (purchased from a supplier) was the only major failure.1986With the durability point proven in racing, Holtzberg shifted his focus to mass production. With Amoco out of the picture, he changed from Torlon to more affordable phenolic resin, the first commercial polymer and the material Henry Ford used to bind his soybean fibers.1990Holtzberg established Composite Castings, now located in West Palm Beach, Florida.19982002Three patents covering technology related to the casting of phenolic or epoxy resin reinforced with fiberglass were issued to Holtzberg. More than a dozen licensees now use his technology for rapid prototyping and other applications.2009Composite Casting formed a strategic partnership with resin supplier Huntsman Chemical.2010A strategic partnership with carbon-fiber supplier Toho Tenax Americas was signed.2011Composite Castings manufactured a dozen experimental carbon-fiber-composite versions of Fords 2.0-liter Duratec four-cylinder engine block.

20Torlon PropertyTest methodunitsneat PAI30% GF PAI30% CF PAITensile StrengthASTM D 638MPa (kpsi)152 (22.0)221 (32.1)221 (32.0)Tensile ModulusASTM D 638GPa (kpsi)4.5 (650)14.5 (2,110)16.5 (2,400)Tensile ElongationASTM D 638%7.62.31.5Flexural StrengthASTM D 790MPa (kpsi)241 (34.9)333 (48.3)350 (50.7)Flexural ModulusASTM D 638GPa (kpsi)5.0 (730)11.7 (1,700)16.5 (2,400)Compressive StrengthASTM D 695MPa (kpsi)221 (32.1)264 (38.3)254 (36.9)Shear StrengthASTM D 732MPa (kpsi)128 (18.5)139 (20.1)119 (17.3)Izod Impact Strength-UnnotchedASTM D 4812J/m (ftlb/in)1070 (20)530 (10)320 (6)Heat Deflection Temperature @ 264 psiASTM D 648C (F)278 (532)282 (540)282 (540)Coefficient Linear Thermal ExpansionASTM D 696ppm/C (ppm/F)31 (17)16 (9)9 (5)Specific GravityASTM D 7921.421.611.482122

23

24

25Polimotor enginethe Ford Pinto 2.3 Liter, 4 cylinder engine was used as the model. Instead of using the cast-iron block and SOHC Single Over Head Camshaft head, the design incorporated reinforced plastic for the block walls, piston skirts, connecting rods, oil pan and portions of the cylinder head. Bore surfaces, piston crowns and combustion chambers would remain iron or aluminium. Crankshaft and camshaft were to be standard Ford production componentsIt resulted in an engine weighing 200 Lbs (91 kg) instead of the 415 Lbs (189 kg) of the production engine.Still backed by AMOCO, he developed another version of the engine this time using the Ford Cosworth BDA design (DOHC/16 Valves). He bought a Lola T-616 that he equipped with the new engine, this time weighing 73 kg.

26manufactureThe mold is a six-piece aluminum jigsaw puzzle consisting of a base plate, four side panels, and a top cover. A removable core, which forms the water jacket, oil drains, and main oil galley, fits inside. During assembly, the mold also is loaded with various aluminum parts: 71 threaded inserts and five main bearing saddles. After casting, four cylinders are placed in the water jacket.

27Manufacture After prepping the mold, epoxy resin and six-mm-long carbon fibers are stirred together in an industrial mixer. The resulting batter, which has the consistency of oatmeal, is warmed slightly and then poured into the mold. Its left to cure for two hours.After casting, the main bearing saddles are line bored and the cylinders are cut to accept linersHoltzberg plans on switching to a molybdenum plasma spray coating in place of aluminum cylinder liners to trim additional pounds.28Future of composite engines Holtzberg has been developing his composite engine and plans to unveil it in a grand manner this year.Ford had plans to try out a composite engine, but after construction of a prototype plans have been shelved. Hopefully they will be revisited. BMW says it is working on its own composite engine, which is in the early stages of developement.29Thank you 30