In this contribution Audi describes how, in future, the lightweight material magnesium can be used in engines subject to extreme loads if special detail design solutions and new creepresistant alloys are adopted. To compensate for the drawbacks of magnesium, AUDI has developed a new crankcase concept in which the magnesium structure is reinforced by local material engineering in critical areas. The result of this development is a compact, multi-functional cylinder insert made of aluminium which is incorporated into the magnesium block using a pressure die-casting process. It combines the typical functions of an engine block, namely cylinder bores, threads for mounting the cylinder head, threads for the main bearing caps and a water jacket (for engine cooling). The special feature of this engineering concept is that both open-deck and closed-deck engine blocks for high peak pressures can be produced by die-casting. So far this advantage has only been available with sand cast or gravity die-cast engine blocks.
Audi hybrid magnesium technology - a new approach to the lightweight engine block
Audi-Hybrid-Magnesium-Technologie - ein neuer Lösungsansatz für den Leichtbau von Motorblöcken
2004
9 Seiten, 10 Bilder, 4 Quellen
Aufsatz (Konferenz)
Englisch
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