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Development of High-pressure Diecast Magnesium Intake Manifold

Article of Honda R&D Technical Review Vol.17 No.2

Summary

A magnesium high-pressure diecast (Mg HPDC) intake manifold has been used in the newly developed V6 Integrated Motor Assist (IMA) engine on the ACCORD Hybrid for the North American market.
The body of the intake manifold features the same split structure used in the alminum high-pressure diecast (AI HPDC) intake manifold fitted in the Honda ELYSION. The two parts of the body are sealed with a formed in-place gasket (FIPG). This FIPG is also used in Honda’s high-pressure diecast magnesium transmission case. A modified version of a metal gasket has been used for the seal of fuel injector base.
The new magnesium high-pressure diecast (Mg HPDC) intake manifold is 44% lighter than a conventional aluminum low-pressure diecast (Al LPDC) intake manifold and 33% lighter than an Al HPDC intake manifold.

Reference

(1) Miyashita, H., Nakata, M., Sakata, M., Hayakawa, Y., Matsumura, S.: Development of a Lightweight Manual Transmission Case of a Heat-Resistant Magnesium Alloy, Honda R&D Technical Review, Vol. 14, No. 2, p. 135-142
(2) Koike, S., Washizu, K., Tanaka, S., Baba, T., Kikawa, K.: Development of Lightweight Oil Pans Made of a Heat-Resistant Magnesium Alloy, HONDA R&D Technical Review, Vol. 12, No. 1, p. 167-174

Author (organization or company)

Kazuhiro WASHIZU(Tochigi R&D Center)、Ikuo TAKEISHI(Tochigi R&D Center)、Naoki SATO(Tochigi R&D Center)、Hidetaka OGISHI(Tochigi R&D Center)、Masamune TABATA(Tochigi R&D Center)

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