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The science and technology of materials in automotive engines

H Yamagata, Yamaha Motor Co Ltd, Japan

 - provides a detailed introduction to the nature of materials used in automotive engines
 - essential reading for engineers, designers, lecturers and students in automotive engineering
 - written by a renowned expert in the field

The science and technology of materials in automotive engines provides an introductory text on the nature of the materials used in automotive engines. It focuses on reciprocating engines, both four and two stroke, with particular emphasis on their characteristics and the types of materials used in their construction. The book considers the engine in terms of each specific part: the cylinder, piston, camshaft, valves, crankshaft, connecting rod and catalytic converter. The materials used in automotive engines are required to fulfil a multitude of functions. It is a subtle balance between material properties, essential design and high performance characteristics. The science and technology of materials in automotive engines describes the metallurgy, chemical composition, manufacturing, heat treatment and surface modification of these materials. It also includes supplementary notes that support the core text.

The book is essential reading for engineers and designers of engines, as well as lecturers and graduate students in the fields of automotive engineering, machine design and materials science looking for a concise, expert analysis of automotive materials.

ISBN 1 85573 742 6
ISBN-13: 978 1 85573 742 6
August 2005
328 pages  234 x 156mm  hardback  
£160.00 / US$270.00 / €190.00

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About the author

Professor Yamagata joined Yamaha Motor Co. Ltd, Japan, after obtaining his engineering doctorate from Tohoku University. He has received numerous awards for outstanding engineering and scientific achievements.

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Contents

Engines
 - The reciprocating engine: the four-stroke engine, the two-stroke engine, the diesel engine
 - Advantages and disadvantages of reciprocating engines
 - Engine components and typical materials: components, typical materials
 - Recent trends in engine technology
 - References

The cylinder
 - Structures and functions
 - The cast iron monolithic block: honing, lubrication and oil consumption, improvement of wear resistance of cast iron blocks
 - The compact graphite iron monolithic block
 - Aluminium blocks with enclosed cast iron liners to improve cooling performance
 - Thermal distortion and heat discharge: how does the cylinder enclosing a press-fit liner deform with heat? Powder metallurgical aluminium liner improves heat transfer
 - Improving engine compaction with surface modifications: shortening the bore interval, chromium plating, Ni-SiC composite plating, thermal spray, the hyper-eutectic Al-Si block, cast-in composite
 - Casting technologies of the aluminium cylinder blocks: sand casting, lost foam process, high-pressure die casting, gravity die casting, low-pressure die casting, squeeze die casting
 - Open and closed deck structures
 - The two-stroke cycle engine cylinder
 - Conclusions
 - References and notes

The piston
 - Structures and functions: the use of Si to decrease the thermal expansion of aluminium
 - Manufacturing process: casting, modifying the distribution of Si crystal
 - Piston design to compensate thermal expansion
 - Heat treatment: age hardening and age softening, hardness measurement estimates the piston temperature during operation
 - Reinforcement of the piston ring groove
 - The high strength piston: strength of piston materials at high temperatures, the lightweight forged piston, powder-metallurgical aluminium alloy raises high temperature strength, the iron piston
 - Conclusions
 - References and notes

The piston ring
 - Functions
 - Suitable shapes to obtain high power output
 - Ring materials: flaky graphite cast iron, use of spherical graphite cast iron to improve elastic modulus and toughness, using steel to generate lightweight rings
 - Designing the self-tension of rings: the distribution of contact pressure and tension, tensioning
 - Surface modification to improve friction and wear: surface modifications during running-in, surface modifications to improve durability
 - Conclusions
 - References and notes

The camshaft
 - Functions
 - Tribology of the camshaft and valve lifter
 - Improving wear resistance of the cam lobe: chilled cast iron, analysis of chemical composition of cast iron before pouring, finishing – boring and grinding, composite structures
 - Reducing friction in the valve train
 - Conclusions
 - References and notes

The valve and valve seat
 - Functions
 - Alloy design of heat-resistant steels: martensitic steel, austenitic steel
 - The bonding valve using friction welding
 - Increasing wear resistance: stellite coating, the Ni-based superalloy valve
 - Lighter valves using other materials: ceramic, titanium alloy
 - The valve seat
 - Conclusions
 - References and notes

The valve spring
 - Functions
 - Steel wires
 - Coiling a spring
 - Improving fatigue strength by shot peening
 - The cylinder head
 - Conclusions
 - References and notes

The crankshaft
 - Functions
 - Types of crankshaft: the monolithic crankshaft, the assembled crankshaft
 - Rigidity
 - Forging: deformation stress, recrystallization, hot forging, cold and semi-hot forging, combination forging
 - Surface-hardening methods: carburizing, nitriding, nitrocarburizing, carbonitriding, ion nitriding, induction hardening
 - Micro-alloyed steel
 - Strengthening
 - Conclusions
 - References and notes

The connecting rod
 - Functions
 - The monolithic con-rod
 - The needle roller bearing: fatigue failure, factors affecting the life of bearings, secondary refining after steel-making
 - The assembled con-rod: structure and material, the con-rod bolt
 - The plain bearing
 - Fracture splitting
 - Conclusions
 - References and notes

The catalyst
 - The development of catalysts for gasoline engines
 - Structures and functions
 - The three-way catalyst: oxidation, reduction and three-way catalysts, deterioration of catalysts
 - The honeycomb substrate: ceramic, metal
 - The development of catalysts to reduce NOx
 - Controlling pollutants at cold start
 - Reducing heat mass and back-pressure: the close-coupled catalytic converter
 - On Board Diagnosis
 - Exhaust gas after-treatment for diesel engines: diesel particulate filters, regenerative methods, expendable catalyst additive, the deNOx catalyst
 - Conclusions
 - References and notes

The turbocharger and the exhaust manifold
 - Functions of the turbocharger
 - The turbine wheel: turbine and compressor designs, investment casting
 - The turbine housing: cast iron, cast steel
 - The exhaust manifold
 - Conclusions
 - References and notes

Appendices
 - A: International standards conversion table for steel alloys
 - B: Function analysis table
 - C: The phase diagram
 - D: Types of cast iron
 - E: Steel making and types of steel
 - F: Creating various properties through heat treatment
 - G: Mechanisms for strengthening metals
 - H: Surface modification
 - I: Joining technology
 - J: Aluminium casting
 - K: Elastic deformation and plastic deformation
 - L: Metal matrix composites in engines