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Federal-Mogul, Mercedes-Benz jointly develop new piston technology

ABR Staff Writer Published 15 September 2011

Federal-Mogul and Mercedes-Benz has jointly developed a piston technology for Daimler’s latest V6 diesel engine that helps to reduce fuel consumption and emissions.

Federal-Mogul has used its DuraBowl piston manufacturing process to build the piston that gives Mercedes-Benz a piston that fully exploits the advances in thermal and mechanical durability.

The use of DuraBowl technology allows piston crown geometries that help to burn fuel more efficiently, improving combustion efficiency and reducing emissions, and helps designers to reduce piston mass while improving performance.

These features improve power output as well as lead to reductions in diesel engine fuel consumption and emissions.

To strengthen the piston crown, which is featured in the large-bowl combustion chamber in Daimler's OM642 V6 3.0-litre diesel, the DuraBowl process uses a high-voltage, high-amperage form of Tungsten Inert Gas arc welding (TIG) to remelt the metal around the bowl rim into a highly durable microstructure.

Federal-Mogul senior vice president of Powertrain Energy Rainer Jueckstock said DuraBowl extends a piston's fatigue resistance by four to eight times under cyclic thermo-mechanical loading.

"The process required extensive development to produce the ideal current and voltage to deliver optimum results and consistent high quality within just 18 months," Jueckstock said.