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Title: High Performance Cast Aluminum Alloys for Next Generation Passenger Vehicle Engines

Abstract

The purpose of this Cooperative Research and Development Agreement (CRADA) between UT-Battelle, LLC, and FCA US LLC (herein referred to individually as “FCA US”) and Nemak USA, Inc., (herein referred to individually as “Nemak”) was to develop higher performance cast aluminum alloy compositions that will enable higher efficiency engines for gasoline passenger on-road vehicles. The cast aluminum engine alloys that are standard across the automotive industry, such as 319 and 356 type aluminum, have now been available for several decades. The design and implementation of higher efficiency passenger automotive engines is currently limited by the absence of economical lightweight materials with improved castability, high temperature strength and fatigue performance. Integrated computational materials engineering (ICME) based iterative design and development of a new class of cast aluminum alloys referred to as ACMZ alloys was performed in this CRADA project. ACMZ alloys have targeted high temperature performance characteristics compared to industry standard 319 and 356 alloys. Several versions of ACMZ alloys were successfully cast (>120 in number) by Nemak into a production aluminum cylinder head design. Three of these cylinder heads were machined successfully on the baseline cylinder head production line, with no machinability issue. One such cylinder head completed a durabilitymore » test schedule at FCA US. Preliminary test results suggest that the new family of cast aluminum alloys may provide opportunity for the automotive industry to increase engine and vehicle efficiency based on increased thermal efficiencies. A commercialization plan has been developed that will allow the introduction of these alloys in commercial vehicles.« less

Authors:
ORCiD logo [1]; ORCiD logo [1];  [2];  [3]
  1. Oak Ridge National Laboratory (ORNL), Oak Ridge, TN (United States)
  2. FCA US LLC, Auburn Hill, MI (United States)
  3. Nemak (Mexico)
Publication Date:
Research Org.:
Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States)
Sponsoring Org.:
USDOE Office of Energy Efficiency and Renewable Energy (EERE)
OSTI Identifier:
1483175
Report Number(s):
ORNL/TM-2018/1064
CRADA NFE-13-04431
DOE Contract Number:  
AC05-00OR22725
Resource Type:
Technical Report
Country of Publication:
United States
Language:
English

Citation Formats

Shyam, Amit, Haynes, James A., Black, Gregg, and Talamantes, Jose. High Performance Cast Aluminum Alloys for Next Generation Passenger Vehicle Engines. United States: N. p., 2018. Web. doi:10.2172/1483175.
Shyam, Amit, Haynes, James A., Black, Gregg, & Talamantes, Jose. High Performance Cast Aluminum Alloys for Next Generation Passenger Vehicle Engines. United States. doi:10.2172/1483175.
Shyam, Amit, Haynes, James A., Black, Gregg, and Talamantes, Jose. Thu . "High Performance Cast Aluminum Alloys for Next Generation Passenger Vehicle Engines". United States. doi:10.2172/1483175. https://www.osti.gov/servlets/purl/1483175.
@article{osti_1483175,
title = {High Performance Cast Aluminum Alloys for Next Generation Passenger Vehicle Engines},
author = {Shyam, Amit and Haynes, James A. and Black, Gregg and Talamantes, Jose},
abstractNote = {The purpose of this Cooperative Research and Development Agreement (CRADA) between UT-Battelle, LLC, and FCA US LLC (herein referred to individually as “FCA US”) and Nemak USA, Inc., (herein referred to individually as “Nemak”) was to develop higher performance cast aluminum alloy compositions that will enable higher efficiency engines for gasoline passenger on-road vehicles. The cast aluminum engine alloys that are standard across the automotive industry, such as 319 and 356 type aluminum, have now been available for several decades. The design and implementation of higher efficiency passenger automotive engines is currently limited by the absence of economical lightweight materials with improved castability, high temperature strength and fatigue performance. Integrated computational materials engineering (ICME) based iterative design and development of a new class of cast aluminum alloys referred to as ACMZ alloys was performed in this CRADA project. ACMZ alloys have targeted high temperature performance characteristics compared to industry standard 319 and 356 alloys. Several versions of ACMZ alloys were successfully cast (>120 in number) by Nemak into a production aluminum cylinder head design. Three of these cylinder heads were machined successfully on the baseline cylinder head production line, with no machinability issue. One such cylinder head completed a durability test schedule at FCA US. Preliminary test results suggest that the new family of cast aluminum alloys may provide opportunity for the automotive industry to increase engine and vehicle efficiency based on increased thermal efficiencies. A commercialization plan has been developed that will allow the introduction of these alloys in commercial vehicles.},
doi = {10.2172/1483175},
journal = {},
number = ,
volume = ,
place = {United States},
year = {2018},
month = {11}
}

Technical Report:

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