Thats an interesting project for sure. Hmm, the aluminum to steel bonding still has some flaws, but it would be cool to have a lighter overall engine. Notice though that they still have all iron firing surfaces.

J-eh

 

Isn't this kinda sounding like Cummins wants to go the Dura-Max way?

I likes my big ol' cast iron Cummins. ;D

 

This will be interesting.
I know a lot of folks will reject an alluminum engine regardless.
But Cummins does have a lot of experience in the diesel engine field.

We'll have to see how this works out.

Rich.

 

that study was done in 2000 Cummins already spent money on the new design common rail engine and associated tooling compliant with 20007 emissions I wouldn't count on new changes for quite awhile wouldn't make economic(sp) sense.Engine and car manufactor do alot of design work that never makes it into production.

 

Engines may change quite slowly but body styles could change quicker. Here are some examples of possible changes we could see in a few years for Dodge:

Dakota Sidewinder with a 488 cu.in. 600 hp Viper V10 engine.
Seen a picture and it looks good.

Dakota T-Rex 6X6. This so far has only a 500 hp V10. It does the 1/4 mile in 16.1 secs and 0-60 in 7.7 secs with .74 g cornering. It has a 26,000 lb tow rating.
Have seen a picture and would not say no to this one. I like the look of the 6X6. Particularly as it could be offered with air suspension.

Dodge M80. Based on Dakota dimensions. 210 hp 3.7l V6. It only weighs 2500 lbs and with that small motor does 0-60 in under 8 secs. Seen a picture and to me it is ugly.

 

[quote author=Lil Dog link=board=8;threadid=23950;start=0#msg225979 date=1071779734]
Hmm, the aluminum to steel bonding still has some flaws, ............... [/quote]

That's for sure. Ran this across one of my old buddies from the AF and he said the corrosive issues alone with the two metals touching would be a bloody nightmare.

 

did I read that right 120 lbs in weight savings??? that dose not seem enough to make it worth while at all !!!
gasers have tried alum engs. they all warp and fail...but alum. dose it much quicker.
and if I read 650.000 mi as a overhaul nu. thats real short in the big truck world..I guess i'm a humbugger I don't like it at all.

 

[quote author=thumper 549 link=board=8;threadid=23950;start=0#msg226607 date=1071883110]
did I read that right 120 lbs in weight savings??? that dose not seem enough to make it worth while at all !!!
gasers have tried alum engs. they all warp and fail...but alum. dose it much quicker.
and if I read 650.000 mi as a overhaul nu. thats real short in the big truck world..I guess i'm a humbugger I don't like it at all.
[/quote]

I wouldn't say ALL aluminum car engines fail. Honda has had excellent success with their aluminum engines. (and their variable valve timing VTEC) Now if you are talking Vega...

 

[quote author=Helicopter Dan link=board=8;threadid=23950;start=0#msg226126 date=1071796381]
that study was done in 2000 Cummins already spent money on the new design common rail engine and associated tooling compliant with 20007 emissions ...[/quote]

That's about the right time frame I'd like to see for incorporating new emissions regs, but doubt that even Bush can stall it that long.

 

Think "cast iron" is good, "aluminum is bad".

Or not.

 

Check this PowerPoint-file with some very informative pages.

http://www.railcan.ca/documents/pres...oTheFuture.ppt

The GE Evolution Series™ locomotive is currently the only freight locomotive in active revenue service that complies with the U.S. Environmental Protection Agency's emissions standards that take effect in 2005. It incorporates the new GEVO-12™, twelve-cylinder diesel engine, which produces the same horsepower as current sixteen-cylinder, 4400 horsepower locomotives, cuts polluting gases and particulate matter by more than 40% and reduces fuel consumption by about 3%. This platform was introduced two years before EPA "Tier 2" emission standards take effect. Greyiron in the block and compact graphite iron in he head.

Doubled pressure, same power, less fuel, 40 % less emissions.
These concepts will be normal procedure to accieve the emissionlimits in the future, even in trucking.

 

That is a 2000 year experiment.

They just poured AL into 1988 dies and went from there.

They made 710 ft/lbs with a non reinforced (iron saddles) aluminum block. On a 12v engine!

Pretty good considering the form they used was meant for iron!

The reinforced block should hold up well and the proprietary cast in place iron combustion chamber inserts should do well. The main saddle reinforcements look to be billet steel ;D.

They save 210#s that makes a CTD engine weigh in like a hemi... maybe lighter?

almost 25% reduction in weight. On bigger engines that is a lot. IMHO its coming and a good idea.

Look at all the 1000+ HP drag engines.... AL blocks and heads.

With the steel inserts in the CC the efficiency of the cummins heads is better than an all aluminum head and its stronger. Also the reinforced block is stronger yet.

If a AL small block chevy can hold up to high hp and tq (plus higher rpms like 8k) with it's compartively puny bearing diameters. The reinforced aluminum when they are done will be just as tough as an all iron cummins engine. Also if you do somehow manage to crack it aluminum is easier to patch up than iron. Some cracks can't be fixed but that is more location and severity than metalurgy. Ever try to weld cast iron?... Welds like crap. Aluminum race blocks get welded all the time after getting pounded by nitromethane... They come back to life.

 

Wait and see. Ford Europe already has seen the difference, and others will wake up.
Ford ran parallell tests with a 2 litre dieselengine with aluminium and CGI. Rising the peak firing pressue step by step. Suddenly the Al-block lost the whole bottom. The CGI-engine rose the pressure to the double, and kept on running.
Kevin O’Neill, director of Ford of Europe’s diesel engine business unit, said: "CGI would make more sense as a material to use for the cylinder blocks of the Duratorq engines at the next major investment upgrade. I would be happy if the engines went to CGI." ( Automotive Engineer 2001 )
The 2,7 liter Ford engine is the lightest in its class with 202 kilos ( 445 lb ) and 440 Nm (99 lb/ft) and a consumtion at some 30 ml/gl.
Wait and see.

 

I don't dought any of it, Diesel engines are finally hitting "main stream" and the car companies are starting to get on the band wagon!! go Cummins!!