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Evolution of residual stress through the processing stages in manufacturing of bore-chilled sand-cast aluminum engine blocks with pressed-in iron liners

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Abstract

To minimize the carbon footprint of the transportation industry, manufacturers and engineers are continuously trying to improve the efficiency of the combustion engine. However, due to the presence of iron cylinder liners in the engine block, high tensile residual stresses are generated during the manufacturing process which leads to a large reduction of the alloy’s useable strength. Thus, the present study utilized neutron diffraction to study, for the first time, the evolution of residual stress of sand-cast aluminum engine blocks that have eliminated the iron cylinder liners from the casting process and mechanically inserted them after heat treatment and machining operations. Moreover, this study also examined the effects that cylinder bore chills have on the resulting residual stress profiles. The replacement of the iron liners shifted the stress mode from purely tension to purely compression until the bore chills were removed. Following the removal of the bore chills, the maximum tensile stress at the top of the cylinder bridge was ~ 70% lower than the engine’s predecessor which was produced with iron liners. Moreover, in the production-ready state (i.e., T7 heat treated and press-fit liners inserted), the stress mode maintains the partially compressive nature, thereby lowering the material’s susceptibility to crack growth and propagation.

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Fig. 1

adapted from Byczynski and Mackay [12])

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Data availability

The raw and processed data required to reproduce these findings are available to download from Mendeley Data [“Data for Residual Stress in I6 Engine Blocks, http://dx.doi.org/10.17632/vz6krysd36.1”].

Code availability

Not applicable.

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Acknowledgements

The authors would like to gratefully acknowledge the support provided by the High Flux Isotope Reactor, a DOE Office of Science User Facility operated by the Oak Ridge National Laboratory. The authors would like to specifically thank local ORNL scientists Dr. Jeffrey Bunn and Dr. Chris Fancher. Finally, the authors sincerely appreciate the contribution from Dr. Houman Alipooramirabad and the entire research team at the High Performance Powertrain Materials laboratory.

Funding

This work was funded by Dr. Dimitry Sediako’s Natural Science and Engineering Research Council (NSERC)—Collaborative Research and Development (CRD) grant (CRDPJ5377770-18, Development of Aluminum Casting and FSW Technologies for Next-Gen Automotive Powertrains). The research described in this paper was supported by funding from the Australian Nuclear Science and Technology Organisation (ANSTO) through Proposals DB8083 and P7274.

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Authors and Affiliations

  1. High Performance Powertrain Materials Laboratory, University of British Columbia – Okanagan, 1137 Alumni Ave, Kelowna, V1V 1V7, Canada

    Joshua Stroh & Dimitry Sediako

  2. Nemak of Canada Corporation, 4655 G.N. Booth Drive, Windsor, ON, N9C 4G5, Canada

    Anthony Lombardi & Glenn Byczynski

  3. ANSTO, New Illawarra Rd, Lucas Heights, Sydney, NSW, 2234, Australia

    Mark Reid & Anna Paradowska

  4. School of Civil Engineering, The University of Sydney, Sydney, NSW, 2006, Australia

    Anna Paradowska

Authors
  1. Joshua Stroh
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  2. Dimitry Sediako
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  3. Anthony Lombardi
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  4. Glenn Byczynski
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  5. Mark Reid
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  6. Anna Paradowska
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Contributions

All authors contributed to the study conception and design. Material preparation was performed by Joshua Stroh, Dimitry Sediako, Anthony Lombardi, and Glenn Byczynski. Data collection and analysis were performed by Joshua Stroh, Dimitry Sediako, Mark Reid, and Anna Paradowska. The first draft of the manuscript was written by Joshua Stroh, and all authors commented on all versions of the manuscript. All authors read and approved the final manuscript.

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Correspondence to Joshua Stroh.

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Stroh, J., Sediako, D., Lombardi, A. et al. Evolution of residual stress through the processing stages in manufacturing of bore-chilled sand-cast aluminum engine blocks with pressed-in iron liners. Int J Adv Manuf Technol 120, 4693–4705 (2022). https://doi.org/10.1007/s00170-022-09059-6

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