You will find the figures mentioned in this article in the German issue of MTZ 02/2006 beginning on page

124.

Hochfeste Zylinderlaufbuchsen fr Dieselmotoren

High-performance Cylinder Liners for Diesel Engines

Permanently increasing pressure and temperature conditions in the combustion chamber of turbocharged low engine-out emission diesel motors (EU5, US 07 and US 10) are taking todays standard cast iron cylinder liner materials to their limits in terms of strength and wear resistance primarily in commercial vehicles. Stringent emissions legislation and engine-internal optimization measures that have considerable impact on the design of cylinder liners are the key drivers. To support the continuing engine optimization, Federal-Mogul has developed two new high-performance cylinder liners materials, which are presented here for the first time.

1 Introduction
Emissions legislation that is getting ever more stringent on a global scale is increasingly driving the development of engine components for commercial vehicles. Emission standards such as EU 5 and US 07/US 10 pose new challenges to the development of commercial vehicle diesel engines related to exaust gas recirculation (EGR). Higher EGR rates und the particulate filter, which reduce the engine power output, are sometimes compensated by adding displacement. To limit the complexity of developing a new engine, one option is to reduce the liner wall thickness. That, however, can only be

Authors:
Steffen Hoppe and Eric Fritsche

done, if the liner material has a substantially higher strength. Added challenges result from development work that seeks to lower fuel and oil consumption that optimizes the diesel combustion process by increasing the cylinder peak pressure to up to 220 bar and varyies the injection timing (phasing). It takes materials with a high level of ultimate tensile strength and a high Youngs modulus (modulus of elasticity) to minimize cylinder distortion and thus lower oil consumption. Todays standard materials offer no sufficient levels of strength reserve. The new cast iron materials GOE323 and GOE330 are developments which Federal-Mogul utilizes for high and maximum stress conditions.
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MATERIALS

Cylinder Liners

2 High-performance Cylinder Liners for Commercial Vehicle Applications

New developments in the commercial vehicle area for instance ask for tensile strengths of 340 to 400 MPa and a Youngs modulus of 130 to 150 GPa. The material developments for cylinder liners as portrayed here are cast iron materials that have been strength optimized in different ways: GOE323 (GJL) is a micro alloy cast iron with flake graphite. GOE330 (GJV) is a compacted graphite cast iron and belongs to the group of ductile cast irons.

2.1 Mico Alloy Cast Iron with Lamellar Graphite

In a cast iron material with flake graphite the carbon surplus has the shape of thin, irregularly shaped graphite laminas. As a rule cast iron of this type has a comparatively low tensile strength, however, this is combined with a good level of thermal conductivity and good damping properties plus a low corrosion susceptibility - all of which are welcome characteristics for engine applications. The material GOE323 (GJL) shows a fine pearlitic microstructure (mixture of the phases ferrite and cementite/carbide of iron) with fine graphite flakes of the E and A type according to ASTM (American Society for Testing and Materials standard) with a length of between 4 and 6 only in the matrix as well as a maximum of 5 per cent ferrite plus additional special carbides of iron, Figure 1. Sophisticated alloy technology ensures a graphite morphology mainly of the ASTM type E, wich means an increasement of strength as compared to common grey cast iron alloys. An enhancement of fatigue life is also related to the graphite type specified above, due to its damping effect on the susceptibility to notching. Adding perlite stabilisators plus Cr, Mo and Ni increases the mechanical properties significantly. At a minimum of 330 MPa tensile strength and a Youngs modulus of at least 115 GOE323 has the characteristics of a high strength cast iron material.

GPa the GOE330 material is a maximum strength material. As is well known the manufacturing of GJV is only possible by tightly controlling certain casting process parameters [1]. Federal Mogul has succeeded in finding a process that is reliable both in the metallurgical field and as far as the production method is concerned. This process does not include adding any helping substances such as Titanium (Ti) to support the vermicular development as this would cause a significantly poorer machinability due to carbide of titan precipitation in the microstructure [2]. By exactly controlling the Mg alloy and its output (efficiency) the nodular structure of GOE300 can be defined within in tight limits. Adding alloy components ensures a finely developed pearlitic base microstructure with a low ferritic content of maximum 5 per cent, which has the above mentioned influence on the graphite modification but also has a strong, positive influence on fatigue strength and incipient cracking. The centrifugal casting that is used as the sole method to manufacture GOE330 ensures a uniformly dense structure throughout the complete cylinder liner as a result to the centrifugal forces.

strength levels of 380 MPa and a Youngs modulus of 140 GPa minimum. Based on cast iron with lamellar graphite the development efforts will target a further increase of strength and Youngs modulus beyond the already high level of GOE323 (GJL). As discussed above the excellent properties of GOE330 already fulfil the requests from the material property point of view. Rather the development work will seek for an improved machinability which is important from the cost angle. An optimized casting process seems to be a promising stragey in combination with appropriate new machining technology. Even higher EGR rate levels, which cause more particulate drag-in, make wear resistance a growing issue. In a situation that is also characterized by longer service intervals the cylinder liner topography has an important influence [3].

5 Conclusion
The high performance and maximum performance cylinder liner materials GOE323 and GOE330 provide engine designers with suitable material options for new approaches to optimizing engine-out emissions as this means adding stress on the cylinder system by increasing pressure, temperature and particulate drag-in (EGR). The materials are designed for the rapidly growing demands on tensile strength and wear resistance that are to be expected. The improved material strength also supports the strategy to compensate the loss of power caused by high EGR rates by adding displacement and reducing liner wall thickness to minimize the effects on the engine dimensions. Further development will increasingly focus on improved cavitation characteristics and the minimization of liner distortion.

3 Cylinder Liner Properties

The new materials have been subjected to several tests to determine the material and product properties. For a liner material the dynamic properties are the most important results besides the static/mechanic properties and the wear properties. GOE330 achieves top results in this respect, Table 1. The measured fatigue strength (rotating beam fatigue test) of 278 MPa is 125 per cent higher than that of conventional grey cast. The GOE323 material achieves a value of 190 MPa which is notably high for a grey cast that has not been heat treated. This result translates into a fatigue strength gain of 70 MPa or around 60 per cent on conventional grey cast. The engine operation wear characteristics of the liner materials portrayed here meet the life endurance standards for commercial vehicles with or withour EGR. A combination with surface hardening of the cylinder running surface has been successfully engine tested in particular with combustion parameters typically valid in North America, Figure 3.

References
[1] Lampic-Oplnder, M.: Gueisen mit Vermiculargrafit GJV Teil 1: Metallurgische Grundlagen. In: Gieerei-Praxis 1/2001, Fachverlag Schiele & Schn, Berlin [2] Lampic-Oplnder, M.: Gueisen mit Vermiculargrafit GJV Teil 4.1: Zerspanen - Einflugren. In: Gieerei-Praxis 8/2001, Fachverlag Schiele & Schn, Berlin [3] Robota, A., Zwein, F.: Einfluss der Zylinderlaufflchentopografie auf den lverbrauch und die Partikelemission eines DI-Dieselmotors. In: MTZ 60 (1999), Vieweg Verlag, Wiesbaden

2.2 Grey Cast with Compacted Graphite

The GOE330 (GJV) material is a cast iron with compacted or vermicular graphite that is distibuted in the microstructure in the shape of vermicula (= shaped like tiny worms), Figure 2. Similar to the process of making spheroidal graphite cast iron the graphite modification is caused by adding a magnesium alloy. At a tensile strength of at least 500 MPa and a Youngs modulus of 140
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4 Outlook
Both materials are in the phases of series production or production ramp-up for commercial vehicle manufacturers. Continually higher engine requirements will demand