A high-strength aluminum cylinder block manufactured using a new production process, ASCT (Advanced Semisolid Casting Technology) has been adopted for the newly developed 2.2L 4-cylinder i-CTDi (Intelligent Common rail Turbo Diesel Injection) diesel engine fitted in the new Accord to be marketed in Europe. In the production process, a semisolid aluminum is used during high-pressure die-casting. In addition, newly developed pressure resistant sand cores are used to mold the closed deck. Heat treatment is conducted to ensure a high level of materials strength.To respond to the high load on the crankshaft journal, die-cast aluminum lower block with cast iron bearing caps inserts are employed. Adopting the dummy head honing to reduce bore deformation and offset cylinders have enabled the achievement a lightweight and compact cylinder configuration matched to the high combustion pressure of the latest diesel engines, while maintaining a high level of quietness.Thanks to these counter measurements, a 30% weight reduction in the new cylinder block has been achieved compared to that of the conventional cast iron diesel engines of the same displacement.


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    Title :

    Development of a High-Strength Aluminum Cylinder Block for Diesel Engine Employing a New Production Process


    Additional title:

    Sae Technical Papers


    Contributors:

    Conference:

    SAE 2004 World Congress & Exhibition ; 2004



    Publication date :

    2004-03-08




    Type of media :

    Conference paper


    Type of material :

    Print


    Language :

    English




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