Fiat Chrysler and Nemak develop a new aluminium alloy in collaboration with ORNL for cylinder blocks and heads

A new blend of aluminium alloy has been developed by engineers from Fiat Chrysler, Mexican engine parts supplier Nemak in collaboration with Tennessee's Oak Ridge National Laboratory for cylinder blocks and heads. The new alloy will raise the optimum temperature range from 390 degrees currently to about 572 degrees.

Hotter running engines are likely to offer better fuel economy and control emissions. Fiat Chrysler is considering possible use of this new alloy for use in their upcoming cylinder heads.

"Cylinder head alloys are the most demanding application in an engine, if you consider the fact that the casting is smaller than the block — but more complex because other parts are attached to it," says Amit Shyam, Oak Ridge's lead researcher on the project.

"It's more demanding from a thermal-mechanical aspect as well. The head sees many thermal cycles. If that was solved, it would be a very major advancement for better engine materials. That's why we focused on cylinder head alloys for initially lighter-duty automotive engines," he added.

Due to the stricter Corporate Average Fuel Economy (Café) Regulations, automakers are under pressure to meet the new emission standards. The targets set by the Obama administration continue to stay, despite efforts to roll back federal fuel economy standards. Automakers have no option but to come up with cars that emit lesser CO2. Hotter-running internal combustion engines will therefore be a critical area of interest for the automotive sector in the next decade. This encourages more focus on the area of improved thermal efficiency. An engine is likely to run more efficiently if it wastes less heat.  Automakers are focusing hard on making big gains in improving thermal efficiency.

FCA and Nemak continued to evaluate the alloy’s performance and durability in engine applications through internal testing throughout 2018. FCA will need a few years to roll off the production line for the new cylinder heads.

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