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1 Introduction
Emissions legislation that is getting ever more stringent on a global scale is increasingly driving the development of engine components for commercial vehicles. Emission standards such as EU 5 and US 07/US 10 pose new challenges to the development of commercial vehicle diesel engines related to exaust gas recirculation (EGR). Higher EGR rates und the particulate filter, which reduce the engine power output, are sometimes compensated by adding displacement. To limit the complexity of developing a new engine, one option is to reduce the liner wall thickness. That, however, can only be
Authors:
Steffen Hoppe and Eric Fritsche
done, if the liner material has a substantially higher strength. Added challenges result from development work that seeks to lower fuel and oil consumption that optimizes the diesel combustion process by increasing the cylinder peak pressure to up to 220 bar and varyies the injection timing (phasing). It takes materials with a high level of ultimate tensile strength and a high Youngs modulus (modulus of elasticity) to minimize cylinder distortion and thus lower oil consumption. Todays standard materials offer no sufficient levels of strength reserve. The new cast iron materials GOE323 and GOE330 are developments which Federal-Mogul utilizes for high and maximum stress conditions.
MTZ 02/2006 Volume 67 23
MATERIALS
Cylinder Liners
GPa the GOE330 material is a maximum strength material. As is well known the manufacturing of GJV is only possible by tightly controlling certain casting process parameters [1]. Federal Mogul has succeeded in finding a process that is reliable both in the metallurgical field and as far as the production method is concerned. This process does not include adding any helping substances such as Titanium (Ti) to support the vermicular development as this would cause a significantly poorer machinability due to carbide of titan precipitation in the microstructure [2]. By exactly controlling the Mg alloy and its output (efficiency) the nodular structure of GOE300 can be defined within in tight limits. Adding alloy components ensures a finely developed pearlitic base microstructure with a low ferritic content of maximum 5 per cent, which has the above mentioned influence on the graphite modification but also has a strong, positive influence on fatigue strength and incipient cracking. The centrifugal casting that is used as the sole method to manufacture GOE330 ensures a uniformly dense structure throughout the complete cylinder liner as a result to the centrifugal forces.
strength levels of 380 MPa and a Youngs modulus of 140 GPa minimum. Based on cast iron with lamellar graphite the development efforts will target a further increase of strength and Youngs modulus beyond the already high level of GOE323 (GJL). As discussed above the excellent properties of GOE330 already fulfil the requests from the material property point of view. Rather the development work will seek for an improved machinability which is important from the cost angle. An optimized casting process seems to be a promising stragey in combination with appropriate new machining technology. Even higher EGR rate levels, which cause more particulate drag-in, make wear resistance a growing issue. In a situation that is also characterized by longer service intervals the cylinder liner topography has an important influence [3].
5 Conclusion
The high performance and maximum performance cylinder liner materials GOE323 and GOE330 provide engine designers with suitable material options for new approaches to optimizing engine-out emissions as this means adding stress on the cylinder system by increasing pressure, temperature and particulate drag-in (EGR). The materials are designed for the rapidly growing demands on tensile strength and wear resistance that are to be expected. The improved material strength also supports the strategy to compensate the loss of power caused by high EGR rates by adding displacement and reducing liner wall thickness to minimize the effects on the engine dimensions. Further development will increasingly focus on improved cavitation characteristics and the minimization of liner distortion.
References
[1] Lampic-Oplnder, M.: Gueisen mit Vermiculargrafit GJV Teil 1: Metallurgische Grundlagen. In: Gieerei-Praxis 1/2001, Fachverlag Schiele & Schn, Berlin [2] Lampic-Oplnder, M.: Gueisen mit Vermiculargrafit GJV Teil 4.1: Zerspanen - Einflugren. In: Gieerei-Praxis 8/2001, Fachverlag Schiele & Schn, Berlin [3] Robota, A., Zwein, F.: Einfluss der Zylinderlaufflchentopografie auf den lverbrauch und die Partikelemission eines DI-Dieselmotors. In: MTZ 60 (1999), Vieweg Verlag, Wiesbaden
4 Outlook
Both materials are in the phases of series production or production ramp-up for commercial vehicle manufacturers. Continually higher engine requirements will demand