New lightweight piston set for market launch
Federal-Mogul has developed a lightweight, high-strength aluminum piston that enables engine manufacturers to increase the power density and efficiency of boosted, direct injected gasoline engines. The Advanced Elastoval II piston enters series production later this year in a new European passenger car, where it contributes to significant gains in fuel economy and reductions in CO2 emissions.
“Federal-Mogul’s innovative Advanced Elastoval II piston is lighter and better equipped to help deliver the higher power outputs our customers need to improve the CO2 emissions and fuel economy of gasoline powertrains,” said Gian Maria Olivetti, vice president, technology and innovation, Federal-Mogul Powertrain Energy. “The application of our expertise to key technologies that enable the development of the next generation of downsized powertrains, aligns with Federal-Mogul’s strategy for sustainable global profitable growth.”
According to Federal-Mogul, the new Advanced Elastoval II piston is lighter, delivers increased power outputs and can withstand the higher pressures that occur late in the combustion cycle of highly charged downsized engines. The Tier 1 says that in the coming years, specific power outputs will increase from current levels of around 95kW/L to 13 kW/L. Peak combustion pressures will rise from 110 bar to 130 bar and even 160 bar in engines using alternative fuels like E100 and CNG.
The Advanced Elastoval II piston architecture is up to 20% lighter than previous generation pistons. And whereas previous wall sections measured 4mm, the latest piston achieves wall sections as thin as 2.5mm.
“Any reduction in wall thickness requires the entire piston structure to be redesigned,” said Arnd Baberg, chief engineer product engineering, Federal-Mogul Powertrain Energy. “Advances in piston design, analysis tools and testing at Federal-Mogul’s global development centers have led to a series of new features that achieve a better stress distribution, enabling a weight optimized design.”
The complex curved side panel forms of the Advanced Elastoval II piston are inclined in two planes and are closer together at the top to support the piston crown, using multiple weight-reducing pockets and crown reinforcing ribs. The piston pin bosses are curved towards the side panels and boss distance is reduced to the minimum possible. The piston’s design uses asymmetric geometries to enable maximum weight reduction.
Several vehicle manufacturers are validating the Advanced Elastoval II piston, with the first scheduled for series production later this year.
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