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Development of Aluminum Cylinder Block for Diesel Engine

Article of Honda R&D Technical Review Vol.16 No.1

Summary

A high-strength aluminum cylinder block manufactured using a new production process, ASCT (Advanced Semisolid Casting Technorogy) 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, the semi-solid aluminum is used during high pressure die-casting. In addition, newly developed pressure-proof sand core are used to mold the closed deck, and heat treatment is conducted to ensure the high level of materials strength.
To respond to the high load on the crankshaft journal, die-cast aluminum lower blocks, in which the cast iron bearing caps are included, are employed. Adopting the dummy head honing and offset cylinders to reduce bore deformation have enabled the achievement 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 measurements, 30% of weight reduction in the new cylinder block has been achieved compared to that of the conventional cast iron diesel engines of the same displacement.

Reference

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Author (organization or company)

Masakazu YAMAZAKI(Tochigi R&D Center)、Atsushi TAKAI(Tochigi R&D Center)、Osamu MURAKAMI(Tochigi R&D Center)、Mitsuhiko KAWABATA(Tochigi R&D Center)、Osami ITO(Honda Engineering Co., Ltd.)、Koichi KUROKI(Honda Engineering Co., Ltd.)

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