WINNER: DuraForm-G91T Aluminum Alloy for Diesel Pistons
2019 - PACE Award Winner
What: High-strength alloy yields piston durability
Innovation: Federal-Mogul is using a new aluminum alloy to produce pistons for diesel engines that boost efficiency and cut carbon dioxide emissions. The high-strength alloy addresses many common reasons why pistons fail, including oxidation, fatigue and increased stress from mechanical and thermomechanical loading. Pistons cast from DuraForm-G91 can weigh nearly one-fourth less than conventional pistons.
First Customer: BMW, Audi
Judge's Citation: While still operating as Federal-Mogul, engineers developed DuraForm-G91, an aluminum alloy for diesel engine pistons. The alloy's chemical composition delivers increased fatigue strength, particularly in the high temperature range associated with highly loaded diesel pistons. In engine testing, the alloy has shown three to five times the fatigue life of current as-cast alloys. In addition to the alloy's composition, a re-engineered casting process was required. Together, the alloy and process allow for piston designs with lower compression height and reduced weight. The resulting benefits of less reciprocating mass and smaller, lighter cylinder blocks contribute to vehicle carbon dioxide emissions reduction.
Web site: federalmogul.com