scholarly journals Development of Repair Techniques for Cast Iron Engine Blocks by Additive Manufacturing

2021 ◽  
Author(s):  
Ryan Dehoff ◽  
Rangasayee Kannan ◽  
Peeyush Nandwana
Keyword(s):  
Cast Iron ◽  
Additive Manufacturing ◽  
Engine Blocks ◽  
Repair Techniques

scholarly journals Life-Cycle and Energy Assessment of Automotive Component Manufacturing: The Dilemma Between Aluminum and Cast Iron

Energies ◽  
2019 ◽  
Vol 12 (13) ◽  
pp. 2557 ◽  
Author(s):  
Konstantinos Salonitis ◽  
Mark Jolly ◽  
Emanuele Pagone ◽  
Michail Papanikolaou
Keyword(s):  
Cast Iron ◽  
Life Cycle ◽  
Aluminum Alloys ◽  
Cylinder Block ◽  
Extensive Literature ◽  
Automotive Components ◽  
Energy Assessment ◽  
Engine Cylinder ◽  
Component Manufacturing ◽  
Engine Blocks

Considering the manufacturing of automotive components, there exists a dilemma around the substitution of traditional cast iron (CI) with lighter metals. Currently, aluminum alloys, being lighter compared to traditional materials, are considered as a more environmentally friendly solution. However, the energy required for the extraction of the primary materials and manufacturing of components is usually not taken into account in this debate. In this study, an extensive literature review was performed to estimate the overall energy required for the manufacturing of an engine cylinder block using (a) cast iron and (b) aluminum alloys. Moreover, data from over 100 automotive companies, ranging from mining companies to consultancy firms, were collected in order to support the soundness of this investigation. The environmental impact of the manufacturing of engine blocks made of these materials is presented with respect to the energy burden; the “cradle-to-grave approach” was implemented to take into account the energy input of each stage of the component life cycle starting from the resource extraction and reaching to the end-of-life processing stage. Our results indicate that, although aluminum components contribute toward reduced fuel consumption during their use phase, the vehicle distance needed to be covered in order to compensate for the up-front energy consumption related to the primary material production and manufacturing phases is very high. Thus, the substitution of traditional materials with lightweight ones in the automotive industry should be very thoughtfully evaluated.

On the Problems with Carbide Formation in Gray Cast Iron

1984 ◽  
Vol 34 ◽  
Author(s):  
R. B. Gundlach ◽  
J. F. Janowak ◽  
S. Bechet ◽  
K. Rohrigtt
Keyword(s):  
Cast Iron ◽  
Gray Cast Iron ◽  
Low Cost ◽  
High Strength ◽  
Gray Iron ◽  
Gray Cast ◽  
Carbide Formation ◽  
Past Half Century ◽  
Iron Technology ◽  
Engine Blocks

Gray iron technology has advanced greatly in the past half century. Much has been learned about the mechanisms of nucleation and solidification and about solid state transformations. This information has alloweu gray iron castings to remain competitive for structural components. Low cost and excellent castability make them versatile for a wide variety of industrial components including engine blocks, cylinder heads, housings, manifolds, hydraulic valve bodies and many other castings of similar complexity. Gray cast iron provides the technical advantages of high strength, soundness, good machinability, dimensional stability and uniformity of properties usually required by such cast components. Achieving these characteristics is dependent, however, on achieving proper and uniform structures tnrougnout all sections of the casting. This objective is reaoily attainable in judiciously alloyed gray cast iron.

An investigation into the suitability of some etching reagents to restoring obliterated stamped numbers on cast iron engine blocks of cars

2012 ◽  
Vol 223 (1-3) ◽  
pp. 53-63 ◽  
Author(s):  
Mohd Farizon Abdul Wahab ◽  
Nurul Izwani Mohamad Ghani ◽  
R. Kuppuswamy
Keyword(s):  
Cast Iron ◽  
Engine Blocks

Additive manufacturing for refrigerant compressors

2020 ◽  
pp. 095440892092205
Author(s):  
C Thomas ◽  
U Hesse
Keyword(s):  
Cast Iron ◽  
Additive Manufacturing ◽  
Driving Factors ◽  
Small Scale ◽  
New Materials ◽  
Lightweight Materials ◽  
Iron Aluminum ◽  
Manufacturing Methods ◽  
Sealing Elements

The requirements for compressors in refrigeration industry become more demanding each year. Requirements regarding efficiency, durability, and also the possibility / demand of dry running machines are the main driving factors. So far, the majority of compressors are mainly manufactured out of cast iron, aluminum, steel, and other metals (not including sealing elements), which lead to high costs as well as weights. The scope of this work includes a demonstration of new manufacturing methods and material choices for small-scale compressors as well as a possible transfer to even larger machines. A detailed look on the potential of different material classes and compounds will be presented. The paper also takes into consideration if the new materials have to be used for lubricated compressors or if there is even a possibility for an operation without any oil. Thermodynamic and strength limits will be pointed out as well as the potential to substitute the nowadays used metals-based components by lightweight materials.

Tubular Composite Material for Hardfacing Layers with Protection Appliance against Abrasive Wears

2007 ◽  
Vol 23 ◽  
pp. 213-216
Author(s):  
P. Motoiu ◽  
Gabriela Popescu ◽  
Horia Binchiciu ◽  
D. Dumitrescu ◽  
S. Ivanescu ◽  
...  
Keyword(s):  
Composite Material ◽  
Cast Iron ◽  
Thermal Spraying ◽  
Surface Protection ◽  
Industrial Sectors ◽  
Engine Blocks

Thermal spraying technologies are an effective way to ensure surface protection against destructive effects of wear, corrosion and oxidizing phenomena which can be applied in majority industrial sectors for improving properties of new parts or for reconditioning worn out parts technology. The powders used in this study are mainly used in the repair of cast iron parts (e.g. engine blocks) and in build - up of press tools for car bodies, threads, turbine-guided vanes, rotating valves and shafts in eccentric presses. Three types of tubular composites based on WC powders were studied which demonstrated that this technology improved their properties.

scholarly journals Life Cycle and Energy Assessment of Automotive Components Manufacturing: The Dilemma Between Aluminium and Cast Iron

2019 ◽  
Author(s):  
Konstantinos Salonitis ◽  
Mark Jolly ◽  
Emanuele Pagone ◽  
Michail Papanikolaou
Keyword(s):  
Cast Iron ◽  
Aluminium Alloys ◽  
Cylinder Block ◽  
Extensive Literature ◽  
Automotive Components ◽  
Energy Assessment ◽  
Engine Cylinder ◽  
Use Phase ◽  
Engine Blocks ◽  
Primary Materials

Considering the manufacturing of automotive components, there exists a dilemma around the substitution of traditional Cast Iron (CI) with lighter metals. Nowadays, aluminium alloys, being lighter compared to traditional materials, are considered as a more environmentally friendly solution. However, the energy required for the extraction of the primary materials and manufacturing of components is usually not taken into account in this debate. In this study, an extensive literature review has been performed to estimate the overall energy required for the manufacturing of an engine cylinder block using (a) cast iron and (b) aluminium alloys. Moreover, data from over 100 automotive companies, ranging from mining companies to consultancy firms, have been collected in order to support the soundness of this investigation. The environmental impact of the manufacturing of engine blocks made of these materials is presented with respect to the energy burden; the “cradle-to-grave approach” has been implemented to take into account the energy input of each stage of the component lifecycle starting from the resource extraction and reaching to the end-of-life processing stage. Our results indicate that although aluminium components contribute towards reduced fuel consumption during their use phase, the vehicle distance needed to be covered in order to compensate for the up-front energy consumption related to the primary material production and manufacturing phases is very high. Thus, the substitution of traditional materials with lightweight ones in the automotive industry should be very thoughtfully evaluated.

scholarly journals Development of volume deposition on cast iron by additive manufacturing

2016 ◽  
Author(s):  
Niyanth Sridharan ◽  
Ryan R. Dehoff ◽  
Brian H. Jordan ◽  
Suresh S. Babu
Keyword(s):  
Cast Iron ◽  
Additive Manufacturing

Thermal Spraying of Cylinder Bores With the PTWA Internal Coating System

2007 ◽  
Author(s):  
K. Bobzin ◽  
F. Ernst ◽  
J. Zwick ◽  
T. Schlaefer ◽  
D. Cook ◽  
...  
Keyword(s):  
Cast Iron ◽  
Co2 Emissions ◽  
Thermal Spray ◽  
Thermal Spray Technology ◽  
Thermal Spraying ◽  
Friction Reduction ◽  
New Production ◽  
Automotive Production ◽  
Engine Blocks ◽  
Engine Components

A major goal for the automotive industry over the next years is the reduction in CO2 emissions. This can be accomplished by reducing fuel consumption for new production vehicles and by increased remanufacturing of old worn engines. Both of these objectives can be addressed with the use of PTWA (Plasma Transferred Wire Arc) thermal spray of cylinder bores. Key factors in this development relating to new production engines focus on the reduction in overall vehicle weight and also the improvement of engine efficiency by reducing the internal friction losses. Substantial weight savings can be achieved with the use of aluminum engines. However, most aluminum engines require cast iron liners to be used as the wear surface. Additional weight savings and potential friction reduction can be achieved by replacing these heavy cast iron liners with a low friction, wear resistant PTWA coatings on the cylinder bores. In addition to being applied to new engines for automotive production, this same process can also be used to repair worn cylinder bores in both aluminum and cast iron engine blocks. This technology makes it possible to salvage engine blocks that would otherwise be scrapped. In addition, PTWA thermal spray can be used to reduce costs for engines that are already remanufactured using expensive over-sized pistons. With reduced costs and salvaging previously scrapped components, the use of the thermal spray technology can increase the amount of remanufacturing for critical engine components. The reduced CO2 emissions results from remanufactured components requiring 50% to 80% less energy to produce than the new production manufactured equivalents [1].

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