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MMC Inserts for Engines

Replacement of gasoline engines in light trucks with diesel engines would reduce US transportation energy use by more than 15 percent with comparable reduction in emissions. Engine weight is a major hurdle, with aluminum being the desired material, over the current iron. However, aluminum castings currently lack required stiffness and strength at operating temperatures.

Foster-Miller completed a program for the US Army Tank and Automotive Command (TACOM) partnering with a major engine manufacturer and castings producer. Combustion plates were produced from aluminum castings reinforced with metal-matrix composites (MMC). Strength and modulus for our material was nearly double that of the iron standard at normal operating temperatures, while weight was about half. Additional follow-on work with DOE will produce and test a full-scale medium-duty aluminum diesel engine head casting.

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