INNOVATIVE FEDERAL-MOGUL TWO-DIMENSIONAL ULSTRASONIC INSPECTION TECHNIQUE ENABLES HIGH PERFORMANCE PISTONS FOR DIESEL DOWNSIZING
(Thomson Reuters ONE) -
Piston design allows major vehicle manufacturer to significantly reduce CO(2
)emissions
Nuremberg, Germany, May 7, 2012. The development of a novel two-dimensional (2D)
ultrasonic analysis system allows Federal-Mogul Corporation (NASDAQ:
FDML) to create a new generation of high performance pistons that enable a
substantial further step in diesel engine downsizing. In its first application,
the greatly improved cooling capability of the company's "raised gallery" piston
allowed a Federal-Mogul customer to achieve a CO(2) reduction of up to 30
percent compared with the previous generation engine without raised gallery
pistons. The first production application of Federal-Mogul's raised gallery
piston also delivers a specific power increase of 25 percent, keeping the piston
at temperatures much lower than the acceptable limit of 400°C. In the same
conditions, a standard piston's bowl rim stresses are 43 percent higher and its
temperature reaches 440°C.
"Diesel downsizing increases specific power output in order to improve fuel
economy and CO(2) emissions and also increases the thermal and mechanical loads
that diesel pistons must withstand," said Gian Maria Olivetti, Federal-Mogul's
vice president for technology and innovation, Powertrain Energy. "With the
development of new highly-loaded engines, the risk of piston failure has
increased substantially as past improvements in materials, design and cooling
concepts have reached their physical limits. Federal-Mogul's innovation in
advanced testing techniques, materials science and manufacturing processes
greatly reduces the limitations placed on diesel downsizing strategies."
Modern diesel pistons have a cooling gallery, through which oil flows
continuously. The position and design of the gallery have a significant impact
on the component's operating temperature and durability. The closer the gallery
is to the piston bowl, the more heat that can be removed, allowing engine
manufacturers to increase combustion temperatures and pressures to improve fuel
economy and CO(2) emissions.
Standard, one-dimensional ultrasonic testing can identify defects but cannot
quantify their size and position. Federal-Mogul's 2D ultrasonic process,
however, provides 125,000 data points in
30 seconds. The technique enables Federal-Mogul engineers to accurately
determine the size and position of defects, providing valuable data for casting
process development. The detailed information provided also ensures consistent
quality in the finished high-precision components.
"In the past, it has been very difficult to cast a piston with optimal size and
location of the cooling gallery," said Dr. Frank T.H. Doernenburg, Federal-Mogul
director of technology, pistons and pins." Federal-Mogul's new 2D ultrasonic
test has removed that barrier. Our process is non-destructive, completely
controls casting process quality and aids advanced casting process development,
giving engine designers substantially more freedom to increase engine
efficiency."
Federal-Mogul validated its 2D ultrasonic technology by dissecting and sampling
hundreds of pistons, correlating the ultrasonic images against destructive
testing methods. The research resulted in the development of software tools as
well as a number of key physical parameters such as probe geometry, wavelength,
beam geometry and focus.
Piston performance can be increased significantly through Federal-Mogul's 2D
ultrasonic testing and analysis process, which is quickly becoming an enabling
technology for more efficient powertrains. This breakthrough in inspection
technology was developed at the company's Nuremberg technical centre and was
recently awarded a 2012 Automotive News PACE Award.
About Federal-Mogul
Federal-Mogul Corporation is a leading global supplier of powertrain and safety
technology and innovation to improve fuel economy, reduce emissions and enhance
vehicle safety. The company serves the world's foremost original equipment
manufacturers of automotive, light, medium-, heavy-duty, aerospace, marine, rail
and off-road vehicles; and industrial, agricultural and power-generation
equipment; as well as providing well-known brands in the global aftermarket.
Federal-Mogul's world-class global engineering, lean manufacturing and
distribution network deliver best-in-class quality products and services at
competitive cost. The company's sustainable global profitable growth strategy
creates value and satisfaction for its customers, shareholders and employees.
Federal-Mogul was founded in Detroit in 1899. The company is headquartered in
Southfield, Michigan, United States and employs 45,000 people in 34 countries.
The company's website is www.federalmogul.com.
# # #
CONTACTS:
Jim Burke
Corporate Communications
248-354-4530
Jim.burke(at)federalmogul.com
Ursula Hellstern
Corporate Communications Europe
+49 (611) 201 9190
Ursula.hellstern(at)federalmogul.com
Federal-Mogul 2D Ultrasonic Inspection Process:
http://hugin.info/151797/R/1608606/510633.jpg
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Source: Federal-Mogul Corporation via Thomson Reuters ONE
[HUG#1608606]
Unternehmensinformation / Kurzprofil:
Datum: 07.05.2012 - 14:01 Uhr
Sprache: Deutsch
News-ID 143344
Anzahl Zeichen: 6312
contact information:
Town:
Southfield
Kategorie:
Business News
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Die Pressemitteilung mit dem Titel:
"INNOVATIVE FEDERAL-MOGUL TWO-DIMENSIONAL ULSTRASONIC INSPECTION TECHNIQUE ENABLES HIGH PERFORMANCE PISTONS FOR DIESEL DOWNSIZING"
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