VNIIMETMASH - Products - Piston from composite materials for engines of new generation


Piston from composite materials for engines of new generation

The technology and device are suggested for production of precise pistons castings for engines with the inorganic (ceramic) fibrous insert and Ni-resist ring. The special production technology for inserts from ceramic fibers of required structure, density and geometry has been developed.

The piston stock (matrix alloy) is the casting aluminium alloy.

The production method is the fluid stamping with through impregnation of the fibrous ceramic insert.

The ceramic insert stock is aluminium-silica fibers with diameter 2...4 m, module is 150 cP, ultimate strength is 1700 MPa, density is 10...20% and unfibrous section is no more than 5%.

The fluid stamping process combined with reinforcement of the piston head through ceramic fibers as compared to the conventional technology permits:

to decrease the metal consumption by 30...40%;
to produce the fine grain structure without defects and gas pores;
to increase mechanical and physical properties of the piston material by 15...20%;
to achieve the high thermal stability of reinforcing effect;
to increase considerably the thermal stability and to decrease the wear piston working surface without thermal cracks appearance on edges;
to improve the piston design and the engine efficiency.

Patents of Russian Federation №№ 2060140, 2093300, 2083301

Silver medal and Diploma of 23 and 26 International salon of inventions in Geneve

Bronze medal and Diploma of 47 International Salon of inventions in Brussel

Results of comparative tests
for composite and standard pistons, %:

Ultimate strength by 350°С	+50
Resistance to wear	+700
Thermal fatigue resistance	+100
Thermal hardness	+30
Coefficient of thermal expansion	-15
Thermal conductivity	-25

Diagram of piston fluid stamping on special press

Automatic casting and stamping unit for fluid stamping of piston blanks (layout)

The casting and stamping unit provides high quality of products, has reliability and high capacity.

Cooperation proposals:

The designing, manufacturing and delivery of a special casting-stamping unit for fluid stamping of piston billets.
The designing, manufacturing and delivery of equipment for the fluid stamping of piston billets.
The delivery of experimental and industrial piston batches.
The formation on a turn-key basis of production capacities for the fluid stamping of pistons and other component.
The selling of the license and know-how for composite pistons production.