Advanced Elastoval II light weight pistons

Scheduled to go into series production later in 2012, Federal Mogul’s new Advanced Elastoval II pistons will further efficiency and performance of direct injection petrol and natural gas engines. Made of lightweight, high tensile aluminium, the Advanced Elastoval II piston will increase peak combustion pressure from 110 up to 160 bar while running on natural fuels like CNG and E100, raising power density and increasing specific power output levels from roughly 95kw/L to 130kw/L. 

“Federal Mogul’s innovative Advanced Elastoval II piston is lighter and better equipped to help deliver the higher power outputs our customers need to improve the CO2 emissions and fuel economy of gasoline powertrains,” said Gian Maria Olivetti, vice president, technology and innovation, Federal Mogul Powertrain Energy. “The application of our expertise to key technologies that enable the development of the next generation of downsized powertrains, aligns with Federal-Mogul’s strategy for sustainable global profitable growth.”

The Advanced Elastoval II piston can deliver increased power output due to its lightweight design. It can also withstand higher pressures that occur late during the combustion cycle of highly charged downsized petrol engines. 

The architecture of the Advanced Elastoval II piston is up to 20 per cent lighter than the previous generation of pistons, partly due to the 2mm wall sections compared to the 4mm wall thickness of previous generation pistons. The piston’s design also uses asymmetric geometries for maximum weight reduction. The curved side panel forms are inclined in two planes that are closer together at the top to support the piston crown with the use of multiple weight reducing pockets and crown reinforcing ribs. The distance between the piston bosses are reduced and to the extent possible while the piston pin bosses are curved towards the side panels. 

The pistons have different skirt widths for the thrust and non-thrust sides to achieve the best compromise between superior NVH, scuffing performance and light weight. The piston reduces skirt width to 50 per cent of bore diameter on the thrust side and 45 per cent of the bore diameter on the non-thrust side without compromising scuffing or NVH levels. 

In the age of engine downsizing Federal Mogul’s Advanced Elastoval II piston ticks all the requirement boxes by offering a light weight design for high performance forced induction petrol engines while improving fuel efficiency, thereby also reducing emissions.  

Car makers have already showed interest in the Advanced Elastoval II piston and are validating its application.