Abstract
Keywords - diesel engine, light weight, HPDC, semi solid casting, new process
Abstract - A high-strength aluminum cylinder block manufactured using a new production process, ASCT (Advanced Semisolid Casting Technology) has been adopted for the newly developed 2.2L 4-cylinder i-CTDi (Intelligent Common rail Turbo Diesel
Injection) diesel engine fitted in the new Accord to be marketed in Europe. In the production process, a semisolid aluminum is used in high-pressure die-casting. In addition, newly developed pressure resistant sand cores are used to mold a closed deck. Heat treatment is conducted to ensure a high level of materials strength.
To respond to the high load on the crankshaft journal, a die-cast aluminum lower block with cast iron bearing caps inserts is employed. To use of the dummy head honing to reduce bore deformation and the adoption of offset cylinders have enabled the achievement of a lightweight and compact cylinder configuration matched to the high combustion pressure of the latest diesel engines, while maintaining a high level of quietness.
Thanks to these measures, a 30% weight reduction in the new cylinder block has been achieved compared to that of conventional cast iron diesel engines of the same displacement.