Process Improvements to Reduce Bonding Gap between Aluminum Cylinder Block and Cast-In Liner and Evaluation through Non-Destructive Techniques TVS Motor Company, Limited

Format:

Book

Conference/Event

Author/Creator:

D, Balachandar, author.

Contributor:

Nataraj, Naveenkumar

Conference Name:

WCX SAE World Congress Experience (2023-04-18 : Detroit, Michigan, United States)

Language:

English

Physical Description:

1 online resource cm

Place of Publication:

Warrendale, PA SAE International 2023

Summary:

Light weight technologies are inevitable in the automotive industry to increase fuel efficiency and meet emission norms. An engine cylinder block is one of the major elements contributing approximately 3-4 % of the automobile weight. Aluminum cylinder block with cast-in liner is almost 40-55 % lighter than a conventional cast iron block [1] and hence the manufacturing processes and challenges associated with them are of high interest. A heterogeneous cast-in liner of gray cast iron in cast aluminum offers a low cost option, but the mechanical bond created between the liner and aluminum interface is prone to gap formation which affects the engine in terms of in-effective heat transfer, distortion and higher blow-by, and thereby high oil consumption and higher emissions. This study aims at reducing this interface bonding gap by in-depth study of critical process parameters involved in manufacturing of cylinder blocks.The study involved a single cylinder petrol engine block manufactured using High Pressure Die Casting (HPDC) process. Using detailed cause and effect analysis, various stages of HPDC like die design, including gating and cooling system were studied and improved using mold flow analysis. Die casting process parameters like die temperature, warm up shots, and biscuit thickness were optimized. Evaluation of bonding gap was carried out using non- destructive techniques like Immersion Ultrasonic Testing and Computed Tomography Testing and a comparative analysis with experimental results of both methods are discussed. Considering initial investment, testing cost, testing time, sensitivity and resolution, a feasible method may be selected for implementation

Notes:

Vendor supplied data

Publisher Number:

2023-01-0880

Access Restriction:

Restricted for use by site license