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CGI can take higher pressures

Increasing use of compacted graphite iron is Comparing engine alloys

being driven by designers seeking more
power and durability from smaller engines. Cast iron
CGI can be cast with thinner walls for less Advantages
weight and physical size. CGI’s greater ● Easy to cast
strength can handle the higher internal ● Easy to machine
pressures that designers use to make fuel ● Inexpensive
combust more completely. This boosts Disadvantages
power and reduces pollutants. ● Prone to wear
● Weak; needs thick-wall castings
Central to the debate is the peak firing Compacted graphite iron
pressure. Since the mid-1990s introduction Advantages
of common-rail injectors, car-engine peak ● Stronger than cast iron
firing pressure levels have risen from 135 ● Thin-wall castings are lighter
bars to 170 bars. Specific power has risen ● Handles high pressure well
too, from 40kW/litre of engine displacement Disadvantages
to 60kW/litre. ● Hard to machine
● Tricky to cast
Swedish supplier Sinter Cast is Already ● More costly than regular cast iron
supporting engine programs requiring 190 Aluminium
bar and 70kW/litre. As peak firing pressures Advantages
increase, the mixing of air and fuel becomes ● Very light
more complete. As a result, power and ● Easy to machine
torque increase, noise levels are lower, fuel Disadvantages
economy improves and CO2 and particulate ● Costly material
emissions are reduced. ● Less rigid; hard to meet Euro 5 limits

But higher thermal loads on the cylinder Where CGI is used compacted graphite
block and the cylinder head can cause iron applications
potential premature fatigue failure. The ● Audi 3.3-liter
properties of CGI allow the cylinder head V-8 diesel
and block to withstand these fatigue loads, ● BMW 3.9-liter
so peak firing pressures can be higher. CGI V-8 diesel
engines can handle loads that aluminium ● Ford/PSA 2.7-liter
engines can’t. Aluminium is half the weight V-6 diesel (June)
of cast iron, but is less rigid, so peak firing ● Audi 3.0-liter
pressure is lower. V-6 diesel (June)
● Audi 2.7-liter
– John Mortimer V-6 diesel (2005)

◆ JULY 12, 2004 AUTOMOTIVE NEWS EUROPE