Jump to content

Alusil: Difference between revisions

From Wikipedia, the free encyclopedia
Content deleted Content added
Correcting/adding technical details; adding more models that use Alusil blocks.
4.5 N/A Cayenne uses Lokasil not Alusil
Tags: Visual edit Mobile edit Mobile web edit
 
(11 intermediate revisions by 9 users not shown)
Line 1: Line 1:
{{Short description|Aluminum-silicon alloy}}
{{Short description|Aluminum-silicon alloy}}
'''Alusil''' as a [[eutectic system|hypereutectic]] [[aluminium]]-[[silicon]] [[alloy]] (EN AC-AlSi17Cu4Mg / EN AC-48100 or A390) contains approximately 78% aluminium and 17% silicon.<ref name=KSPG-AG>{{cite web|title=ALUSIL - Cylinder Blocks for the new Audi V6 and V8 SI engines |url=http://www.kspg-ag.com/pdfdoc/kspg_produktbroschueren/a_audi_zkg_e.pdf |format=PDF |work=KS Aluminium-Technologie AG |publisher=KSPG-AG.com |access-date=13 January 2010 }}{{dead link|date=July 2017 |bot=InternetArchiveBot |fix-attempted=yes }}</ref><ref name=finishing.com>{{cite web|title=What is Alusil coating?|url=http://www.finishing.com/3600-3799/3605.shtml|work=finishing dot com|publisher=finishing.com|access-date=13 January 2010}}</ref> This alloy was theoretically conceived in 1927 by [[Schweizer & Fehrenbach]],<ref name=Rheinmetall>{{cite web|title=Rheinmetall's tradition of automotive excellence|url=http://www.rheinmetall-detec.de/index.php?lang=3&fid=3397|work=Rheinmetall Defence|publisher=Rheinmetall-Detec.de|date=January 2006|access-date=23 May 2020|url-status=dead|archive-url=https://archive.today/20060925031207/http://www.rheinmetall-detec.de/index.php?lang=3&fid=3397|archive-date=25 September 2006}}</ref> of the Badener Metall-Waren-Fabrik, 2a Hermannstraße, Baden-Baden;<ref>{{cite book |title=Addreßbuch Baden-Baden 1926 |place=Baden-Baden |publisher=Ernst Koelblin |pages=49, 80, 185, 375 |url=https://www.baden-baden.de/mam/files/kultur/stadtarchiv/adressbuecher/1926_adressbuch_baden_baden.pdf}}</ref> but practically created only by [[Lancia]]<ref>{{Cite book|title=Pionieri dell'automobile. Lancia, Bazzi, Ferrari|last=Manicardi N.|publisher=Il Fiorino|year=2014|isbn=88-7549-464-9|location=Modena (IT)}}</ref> in the same year, for its car engines. It was further developed by Reynolds<ref>{{Cite journal |date=1971-08-01 |title=REYNOLDS 390 and A390 |url=https://doi.org/10.31399/asm.ad.al0203 |journal=Alloy Digest |volume=20 |issue=8 |doi=10.31399/asm.ad.al0203 |issn=0002-614X}}</ref>, now [[Rheinmetall Automotive|Kolbenschmidt]].<ref name=finishing.com/> In the United States, Chevrolet was the first to Reynolds A390 in the [[Chevrolet Vega]].
'''Alusil''' as a [[eutectic system|hypereutectic]] [[aluminium]]-[[silicon]] [[alloy]] (EN AC-AlSi17Cu4Mg / EN AC-48100 or A390) contains approximately 78% aluminium and 17% silicon.<ref name=KSPG-AG>{{cite web|title=ALUSIL - Cylinder Blocks for the new Audi V6 and V8 SI engines |url=http://www.kspg-ag.com/pdfdoc/kspg_produktbroschueren/a_audi_zkg_e.pdf |work=KS Aluminium-Technologie AG |publisher=KSPG-AG.com |access-date=13 January 2010 }}{{dead link|date=July 2017 |bot=InternetArchiveBot |fix-attempted=yes }}</ref><ref name=finishing.com>{{cite web|title=What is Alusil coating?|url=http://www.finishing.com/3600-3799/3605.shtml|work=finishing dot com|publisher=finishing.com|access-date=13 January 2010}}</ref> This alloy was theoretically conceived in 1927 by [[Schweizer & Fehrenbach]],<ref name=Rheinmetall>{{cite web|title=Rheinmetall's tradition of automotive excellence|url=http://www.rheinmetall-detec.de/index.php?lang=3&fid=3397|work=Rheinmetall Defence|publisher=Rheinmetall-Detec.de|date=January 2006|access-date=23 May 2020|url-status=dead|archive-url=https://archive.today/20060925031207/http://www.rheinmetall-detec.de/index.php?lang=3&fid=3397|archive-date=25 September 2006}}</ref> of Badener Metall-Waren-Fabrik,<ref>{{cite book |title=Addreßbuch Baden-Baden 1926 |place=Baden-Baden |publisher=Ernst Koelblin |pages=49, 80, 185, 375 |url=https://www.baden-baden.de/mam/files/kultur/stadtarchiv/adressbuecher/1926_adressbuch_baden_baden.pdf}}</ref> but practically created only by [[Lancia]]<ref>{{Cite book|title=Pionieri dell'automobile. Lancia, Bazzi, Ferrari|last=Manicardi N.|publisher=Il Fiorino|year=2014|isbn=978-88-7549-464-3|location=Modena (IT)}}</ref> in the same year, for its car engines. It was further developed by Reynolds,<ref>{{Cite journal |date=1971-08-01 |title=REYNOLDS 390 and A390 |url=https://doi.org/10.31399/asm.ad.al0203 |journal=Alloy Digest |volume=20 |issue=8 |doi=10.31399/asm.ad.al0203 |issn=0002-614X}}</ref> now [[Rheinmetall Automotive]].<ref name=finishing.com/> In the United States, Chevrolet was the first to use Reynolds A390 in the [[Chevrolet Vega]].


The Alusil aluminium alloy is commonly used to make [[cylinder liner|liner]]less aluminium alloy [[engine block]]s.<ref>{{cite web|title=High-performance engine blocks for tomorrow’s challenges|url=http://www.kspg-ag.de/index.php?lang=2&fid=444#11|work=Kolbenschmidt Pierburg AG|publisher=KSPG-AG.com|date=12 September 2005|access-date=13 January 2010|url-status=dead|archive-url=https://web.archive.org/web/20120227101531/http://www.kspg-ag.de/index.php?lang=2&fid=444#11|archive-date=2012-02-27}}</ref> There is no coating applied to the cylinder bore and blocks are not honed conventionally. During the manufacturing process, a chemical or mechanical process is used to remove aluminum from the surface of the cylinder bore, exposing a very hard silicon precipitate. These exposed silicon particles, which under a microscope look like small islands, allow for oil to collect in the area surrounding them, thus forming the required tribofilm that supports piston and ring travel.<ref>{{Cite web |title=Latest machining techniques for aluminium cylinder bores (Alusil and Lokasil) |url=https://cdn2.ms-motorservice.com/fileadmin/media/MAM/PDF_Assets/Latest-Machining-Techniques-for-Aluminium-Cylinder-Bores-Alusil-and-Lokasil_51886.pdf}}</ref>
The Alusil aluminium alloy is commonly used to make [[cylinder liner|liner]]less aluminium alloy [[engine block]]s.<ref>{{cite web|title=High-performance engine blocks for tomorrow's challenges|url=http://www.kspg-ag.de/index.php?lang=2&fid=444#11|work=Kolbenschmidt Pierburg AG|publisher=KSPG-AG.com|date=12 September 2005|access-date=13 January 2010|url-status=dead|archive-url=https://web.archive.org/web/20120227101531/http://www.kspg-ag.de/index.php?lang=2&fid=444#11|archive-date=2012-02-27}}</ref> There is no coating applied to the cylinder bore and blocks are not honed conventionally. During the manufacturing process, a chemical or mechanical process is used to remove aluminum from the surface of the cylinder bore, exposing a very hard silicon precipitate. These exposed silicon particles, which under a microscope look like small islands, allow for oil to collect in the area surrounding them, thus forming the required tribofilm that supports piston and ring travel.<ref>{{Cite web |title=Latest machining techniques for aluminium cylinder bores (Alusil and Lokasil) |url=https://cdn2.ms-motorservice.com/fileadmin/media/MAM/PDF_Assets/Latest-Machining-Techniques-for-Aluminium-Cylinder-Bores-Alusil-and-Lokasil_51886.pdf}}</ref>


The pistons used in an Alusil engine block typically have an iron-clad plating or similar coating on the piston skirts to prevent galling of the aluminum pistons when run against the uncoated aluminum cylinder bore. Examples of this coating include Mahle Ferrostan (I & II), FerroTec, or Ferroprint.<ref>{{Cite book |url=https://www.worldcat.org/oclc/831115179 |title=Pistons and engine testing |date=2012 |publisher=Vieweg+Teubner |others=MAHLE GmbH |isbn=978-3-8348-8662-0 |location=Wiesbaden |oclc=831115179}}</ref>
The pistons used in an Alusil engine block typically have an iron-clad plating or similar coating on the piston skirts to prevent galling of the aluminum pistons when run against the uncoated aluminum cylinder bore. Examples of this coating include Mahle Ferrostan (I & II), FerroTec, or Ferroprint.<ref>{{Cite book |url=https://www.worldcat.org/oclc/831115179 |title=Pistons and engine testing |date=2012 |publisher=Vieweg+Teubner |others=MAHLE GmbH |isbn=978-3-8348-8662-0 |location=Wiesbaden |oclc=831115179}}</ref>
Line 19: Line 19:
*Audi [[list of Volkswagen Group petrol engines#5.2 FSI V10 320-331kW (S6/S8)|5.2 FSI V10]]
*Audi [[list of Volkswagen Group petrol engines#5.2 FSI V10 320-331kW (S6/S8)|5.2 FSI V10]]
*Audi/[[Volkswagen]] [[list of Volkswagen Group petrol engines#W12|6.0 W12]]
*Audi/[[Volkswagen]] [[list of Volkswagen Group petrol engines#W12|6.0 W12]]
*[[BMW M52]] [[straight-six engine|I6]]{{fact|date=March 2020}}
*[[BMW M54]] I6
*[[BMW N52]] I6
*[[BMW N52]] I6
*[[BMW M62]] [[V8 engine|V8]]
*[[BMW M62]] [[V8 engine|V8]]
*[[BMW S62]] [[V8 engine|V8]]
*[[BMW N62]] V8
*[[BMW N62]] V8
*[[BMW N63]] V8
*[[BMW N63]] V8
*[[BMW M70|BMW M70/M73]] V12<ref>{{cite web|title=High-tech products for the new and advanced BMW V12|url=http://www.kspg-ag.de/index.php?fid=206&qid=&qpage=0&lang=3|work=Kolbenschmidt Pierburg AG|publisher=KSPG-AG.com|date=10 January 2003|access-date=13 January 2010|url-status=dead|archive-url=https://web.archive.org/web/20120227101556/http://www.kspg-ag.de/index.php?fid=206&qid=&qpage=0&lang=3|archive-date=2012-02-27}}</ref>
*[[BMW M70|BMW M70/M73]] V12<ref>{{cite web|title=High-tech products for the new and advanced BMW V12|url=http://www.kspg-ag.de/index.php?fid=206&qid=&qpage=0&lang=3|work=Kolbenschmidt Pierburg AG|publisher=KSPG-AG.com|date=10 January 2003|access-date=13 January 2010|url-status=dead|archive-url=https://web.archive.org/web/20120227101556/http://www.kspg-ag.de/index.php?fid=206&qid=&qpage=0&lang=3|archive-date=2012-02-27}}</ref>
*[[BMW N74]] V12
*BMW [[BMW S65|S65]] & [[BMW S85|S85]] M Engines
*BMW [[BMW S65|S65]] & [[BMW S85|S85]] M Engines
*[[Mercedes-Benz M112 engine]] V6
*[[Mercedes-Benz M112 engine]] V6
Line 31: Line 31:
*[[Mercedes-Benz W126|Mercedes 560 SEL]] [[Mercedes-Benz M117 engine|M117]] V8
*[[Mercedes-Benz W126|Mercedes 560 SEL]] [[Mercedes-Benz M117 engine|M117]] V8
*[[Mercedes-Benz M119 engine|Mercedes M119]] V8
*[[Mercedes-Benz M119 engine|Mercedes M119]] V8
*[[Mercedes-Benz M120 engine|Mercedes M120]] V12
*[[Porsche 928]] V8
*[[Porsche 928]] V8
*[[Porsche 924|Porsche 924S]] [[inline-four engine|I4]]
*[[Porsche 924|Porsche 924S]] [[inline-four engine|I4]]
Line 36: Line 37:
*[[Porsche 968]] I4
*[[Porsche 968]] I4
*Porsche Cayenne V6 (excluding models with VW VR6 engine which has a cast iron block)
*Porsche Cayenne V6 (excluding models with VW VR6 engine which has a cast iron block)
*[[Porsche Cayenne]] V8<ref name="Rheinmetall" />
*[[Porsche Cayenne]] V8 (excluding 4.5 V8 Naturally Aspirated which uses Lokasil)
*Porsche Panamera V6
*Porsche Panamera V6
*Porsche Panamera V8
*Porsche Panamera V8

Latest revision as of 02:12, 31 October 2024

Alusil as a hypereutectic aluminium-silicon alloy (EN AC-AlSi17Cu4Mg / EN AC-48100 or A390) contains approximately 78% aluminium and 17% silicon.[1][2] This alloy was theoretically conceived in 1927 by Schweizer & Fehrenbach,[3] of Badener Metall-Waren-Fabrik,[4] but practically created only by Lancia[5] in the same year, for its car engines. It was further developed by Reynolds,[6] now Rheinmetall Automotive.[2] In the United States, Chevrolet was the first to use Reynolds A390 in the Chevrolet Vega.

The Alusil aluminium alloy is commonly used to make linerless aluminium alloy engine blocks.[7] There is no coating applied to the cylinder bore and blocks are not honed conventionally. During the manufacturing process, a chemical or mechanical process is used to remove aluminum from the surface of the cylinder bore, exposing a very hard silicon precipitate. These exposed silicon particles, which under a microscope look like small islands, allow for oil to collect in the area surrounding them, thus forming the required tribofilm that supports piston and ring travel.[8]

The pistons used in an Alusil engine block typically have an iron-clad plating or similar coating on the piston skirts to prevent galling of the aluminum pistons when run against the uncoated aluminum cylinder bore. Examples of this coating include Mahle Ferrostan (I & II), FerroTec, or Ferroprint.[9]

BMW switched from Nikasil-coated cylinder walls to Alusil in 1996 to eliminate the corrosion problems caused through the use of petrol/gasoline containing sulfur.

Although similar, Alusil is not to be mistaken with Lokasil which was used by Porsche in the Boxster, Cayman, and 911 models from 1997 through 2008. Lokasil blocks use a freeze cast cylinder sleeve pre-form which is inserted into the casting mold. This preform contains silicon particles suspended in a resin binder. During the casting process, the molten aluminum is injected into the mold and burns off the resin, leaving an area of localized hypereutectic aluminum only in the area of the cylinder bore. The silicon particles are then mechanically exposed in a similar process to an Alusil block resulting in a cylinder block that functions in the same way as one cast out of Alusil.

Although successfully used by many European manufacturers, there are potentially issues associated with engines that use Alusil blocks, namely cylinder bore scoring which occurs when there is a breakdown of the exposed silicon particles in the cylinder bore, resulting in increased oil consumption and excessive piston noise.[10]

Vehicles / Engines using Alusil include:

See also

[edit]

References

[edit]
  1. ^ a b c "ALUSIL - Cylinder Blocks for the new Audi V6 and V8 SI engines" (PDF). KS Aluminium-Technologie AG. KSPG-AG.com. Retrieved 13 January 2010.[permanent dead link]
  2. ^ a b "What is Alusil coating?". finishing dot com. finishing.com. Retrieved 13 January 2010.
  3. ^ a b "Rheinmetall's tradition of automotive excellence". Rheinmetall Defence. Rheinmetall-Detec.de. January 2006. Archived from the original on 25 September 2006. Retrieved 23 May 2020.
  4. ^ Addreßbuch Baden-Baden 1926 (PDF). Baden-Baden: Ernst Koelblin. pp. 49, 80, 185, 375.
  5. ^ Manicardi N. (2014). Pionieri dell'automobile. Lancia, Bazzi, Ferrari. Modena (IT): Il Fiorino. ISBN 978-88-7549-464-3.
  6. ^ "REYNOLDS 390 and A390". Alloy Digest. 20 (8). 1971-08-01. doi:10.31399/asm.ad.al0203. ISSN 0002-614X.
  7. ^ "High-performance engine blocks for tomorrow's challenges". Kolbenschmidt Pierburg AG. KSPG-AG.com. 12 September 2005. Archived from the original on 2012-02-27. Retrieved 13 January 2010.
  8. ^ "Latest machining techniques for aluminium cylinder bores (Alusil and Lokasil)" (PDF).
  9. ^ Pistons and engine testing. MAHLE GmbH. Wiesbaden: Vieweg+Teubner. 2012. ISBN 978-3-8348-8662-0. OCLC 831115179.{{cite book}}: CS1 maint: others (link)
  10. ^ Navarro, Charles (2019). "Understanding Bore Scoring in Al-Si Cylinder Systems" (PDF).
  11. ^ a b "KS Aluminium-Technologie: engine blocks for the new Audi A6". Rheinmetall AG. Rheinmetall.de. August 2004. Retrieved 13 January 2010.[permanent dead link]
  12. ^ "High-tech products for the new and advanced BMW V12". Kolbenschmidt Pierburg AG. KSPG-AG.com. 10 January 2003. Archived from the original on 2012-02-27. Retrieved 13 January 2010.
[edit]