"Federal-Mogul is among the first to develop a range of materials specifically for the requirements of the fast-growing automotive turbocharger and high-performance EGR markets,” said Rainer Jueckstock, Federal-Mogul senior vice president of Powertrain Energy.
The new bushings and guides will be able to withstand the high temperatures and increasingly severe conditions of downsized low CO2 diesel and petrol engines. Engine designers can now push exhaust gas temperatures up to around 1050°C (1922°F), compared with around 800°C (1472°F) for a typical engine application currently.
“Operating at high temperatures can be a considerable challenge, particularly because at very high temperatures no lubrication can be used to reduce friction or wear between moving parts,” said Dr. Bob Pratt, Federal-Mogul’s sintered products research manager.
The new PM components will be manufactured by sintering a blend of powdered metals. Federal-Mogul Corp says that the advantages of PM pressing and sintering include reduced machining and an ability to precisely tailor the composition of the material to match the performance characteristics required for the component. Federal-Mogul also uses PM sintering to manufacture valve seats and guides.
To improve the new materials, the company is also improving the manufacturing processes specifically focused on the new material components. “Every change in composition and part geometry also has an impact on processing and machineability,” Dr. Pratt said. “To achieve improved tool life, reduced scrap and lower process times, we are working with customers to help them develop improved tools and processes that allow efficient machining of these very hard materials.”