Facts on Hydro's V-6 block for Mercedes
(Feb. 2, 2005) Hydro is supplying DaimlerChrysler with a benchmark-setting engine block from aluminium for its new Mercedes V-6 diesel engine. Here are some more facts:
TECHNOLOGY: Hydro has advanced its proprietary Core Package System CPS™ to become the leading technology for complex engine castings. Far-reaching design options allowed the integration of oil and water channels and pre-casting of attached parts, supporting Daimler-Chrysler´s innovative “one-box concept”.
At a V-degree of 72°, the most compact engine architecture in its class achieves a performance-weight ratio of 0.79 KW/kg, up 20 per cent compared with its predecessor, Mercedes´ 5-cylinder inline diesel engine. Cast-in rough iron liners ensure high thermal conductivity and low friction for the engine run. Yet, Hydro´s final aluminium block is saving more than 35 kg compared with a similar engine block in iron.
The casting method has been refined to provide outstanding fatigue strength, even exceeding the level of grey cast iron. Thanks to a combination of contact pouring, chill technique and a fine-tuned alloy, the new block meets the famous Mercedes standard for long-term durability, even at such a tremendous torque level as 510 Nm.
PLANT: To manufacture the new product, Hydro Aluminium Alucast in Dillingen, Germany, has established a third production line for V-engines with a maximum capacity of 350,000 parts per year. The Mercedes order is creating new jobs. In the long run, the Alucast plant workforce may grow to 800.
MARKET: Diesel engines are rapidly approaching 50 per cent of the market for new car registrations in Europe – and now can contribute to the future growth of aluminium use in cars. This will further increase fuel efficiency and facililitate recyclability. Based on this development, Hydro Aluminium Business Unit Castings will increase its market share and provide more viable solutions for engine manufacturing.
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