Review: New piston by Federal-Mogul Corporation

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Higher power output from smaller engines is the mantra for lower CO2 emissions and improved fuel economy. Federal-Mogul Corporation (FMC) has developed an aluminium piston called DuraBowl whose crown is strengthened by locally re-melting the alloy around the bowl, thereby making it last between four and seven times longer than a conventional one.Federal-Mogul senior vice president Rainer Jueckstock says, "Rising specific outputs place higher mechanical and thermal loads on many of the components where Federal-Mogul has considerable expertise. The DuraBowl piston process is an example of how we are succeeding in delivering specialised process technologies that help our customers successfully address these challenges across a range of growing market sectors."

 "Fibre-reinforced pistons increase manufacturing complexity as the molten alloy has to infiltrate the fibres during casting," said Frank Doernenburg, Federal-Mogul director of technology, pistons and pins.  "Furthermore, there is not yet a reliable, non-destructive way to test the integrity of the finished part whereas, with our DuraBowl process, we can do an Eddy Current test to ensure the quality."

 

 "The strength and efficiency of our solution is that the process is physically simple," said Doernenburg.  "The sophistication is in the control of key parameters, which ensure consistent 

quality. The result is a technologically advanced, high-performing and very cost-competitive product when compared to both fibre-reinforced and steel pistons."

 

Doernenburg says, "The re-melting process certainly increases piston life and performance substantially, while at the same time, serving as a contributor to improve fuel efficiency and 

reduce CO2.  A conservative estimate would be a four-fold improvement in the life of any cast piston which suffers from bowl rim failures." Federal-Mogul Corporation is  a premier innovator in the areas of powertrain, sealing, safety and protection. Here is the original press release