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Federal-Mogul’s Nüral® Pistons Reduce CO2 Emission and Fuel Consumption
Federal-Mogul engineers are playing vital roles in helping engine manufacturers achieve new targets for power, durability, fuel efficiency and emissions. We recently sat down with Josef Harrer, Federal-Mogul global director, aluminium piston engineering, to discuss recent trends in engine design as well as the many exclusive material and design characteristics which ensure that, when it comes to pistons, “Nüral gives you more™.”
What should engine rebuilders know about the latest OE piston technologies?>
Because Federal-Mogul is one of the world’s largest piston manufacturers, our Nüral product line for the aftermarket logically reflects OE trends. Each piston is engineered to address the unique operating demands of its application based on our OE involvement as our insight to the specific requirements of the repair environment. Nüral pistons are significantly lighter and stronger today. They also feature a variety of design characteristics that help reduce emissions and increase engine efficiency.
How does piston design reflect the trends in overall engine design?
Piston technology is at the very centre of OEMs’ efforts to increase fuel efficiency, reduce emissions of harmful gases, minimize NVH (Noise, Vibration, Harshness) issues and maximize engine performance and durability. We’re seeing significantly higher specific power output and, of course, higher cylinder pressures and temperatures. It’s our job to develop piston technologies that can thrive in this challenging operating environment while also contributing to reductions in frictional power loss. Each new generation of Federal-Mogul piston technology represents significant progress in these areas.
What role are Federal-Mogul pistons playing in increasing engine performance, efficiency and environmental sensitivity?
Our pistons and other powertrain solutions support these goals through direct and enabling contributions. As an example of a direct contribution, our advanced metallurgies and component designs have allowed us to reduce component weight, mass and friction. This can be seen in the removal of material in non-critical areas, the introduction of smaller piston skirt surfaces and the use of sophisticated low-friction skirt and pin coatings. Our enabling solutions include metallurgical and design enhancements that permit increased cylinder pressures and temperatures, higher specific output and the ability to use alternative fuels.
What is the EconoMiser™ piston and what role will it eventually play in the aftermarket?
EconoMiser™ is an entire research and development program to understand frictional horsepower losses and the influence of several features to improve friction without compromising NVH behaviour and oil consumption. We already have achieved a 34-percent reduction in frictional loss as compared to conventional OE pistons. And we’ve achieved a 45-percent reduction in piston mass while increasing fatigue strength by up to 40 percent. When this technology enters the aftermarket replacement cycle, it will be available exclusively through the Nüral product range.
Will these stronger, longer-running OE piston technologies affect the reparability of engines down the road?
This has been a common concern whenever there has been a significant change in engine design. The use of aluminium cylinder heads caused some concern among rebuilders back in the 1980s. Lighter-weight engine castings were a concern in the ’90s. We’re finding, however, that the engine repair community, supported by OE and aftermarket suppliers such as Federal-Mogul, has the tools and skills to rebuild each new generation of engines. I certainly think this will continue to be the case.
How are piston rings changing for today’s high-output, high-temperature engines?
Rings play a significant role in achieving increased engine efficiency, power, reliability and environmental sensitivity. One of the most significant recent advances in ring technology has been Federal-Mogul’s Goetze Diamond Coating®. GDC® features a chromium-diamond matrix that dramatically reduces wear to the ring face and cylinder bore and improves scuff resistance. This solution is already a preferred choice of OEMs and has been introduced to the Goetze aftermarket range for select applications.
Federal-Mogul has pioneered the use of a “Monosteel” piston in the CV market. How is this technology significant?
The key benefits of Monosteel technology are increased strength at very high combustion pressure and high temperature in heavy duty and industrial diesel engines. Unlike articulated pistons, Monosteel pistons are manufactured entirely from steel and then friction welded into a single piece. This design eliminates bushings and allows for larger oil galleries beneath the piston crown for significantly improved heat transfer.
