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Aleksandr Matveev | Dreamstime
Thiti Tangjitsangiem | Dreamstime
'Availability of new foundry sand is already becoming a challenge, along with the need of providing new solutions to waste management,” according to the director of a metallurgical research center.
Branimir Ritonja | Dreamstime
Automotive cast parts.
Seesea | Dreamstime
Fire photo
Jacek Sopotnicki | Dreamstime
With deoxidized base iron, carbon levels can be increased to 3.30% C and alloying can be completely or nearly eliminated at the same time.

Ford to Debut CGI Engines for North American Trucks

Aug. 31, 2009
New, lighter V-8 set to meet 2011 EPA emission standards
Ford Motor Co. is calling its introduction of a new 6.7-liter, V-8 diesel engine “a new era in Ford diesel technology.” The Power Stroke V-8 turbocharged diesel engine will be the core of a new F-Series Super Duty truck, and the automaker promises the engine will bring improved torque, horsepower and fuel economy to the truck series, as well as more flexibility in fueling. Ford notes that the new engine design will meet the U.S. Environmental Protection Agency’s new 2011 emissions requirements easily. Its fueling options may range up to 20 percent biodiesel and 80 percent petroleum diesel. The new design calls for the engine to be cast of compacted graphite iron rather than the standard gray iron. Ford calls this the first use of a CGI block in a Super Duty-class vehicle in North America, though Ford has used the material in engine blocks in products around the world. CGI is accepted as being stronger than gray iron, so the engine block can be made lighter without foregoing the demands of higher torque and horsepower. The cylinder heads will be cast in aluminum. The automaker has indicated the engines will be built at its Ford Motor Co., S.A. de C.V. - Chihuahua Engine Plant in Mexico. It’s not known where the engine blocks will be cast, though Ford has had CGI V-6 engines blocks produced by Tupy Fundicoes, in Joinville, Brazil. "This all-new diesel engine has been so extensively tested both in the lab and in the real world that we're confident we're giving our customers the most reliable and productive powertrain available today," stated Ford’s Derrick Kuzak, group vice president of Global Product Development. "Our Super Duty customers demand reliability and durability in their trucks so they can deliver the best results for their business and their customers. That's exactly what this engine delivers." Another design change in the 6.7-liter Power Stroke is the inboard exhaust/outboard intake architecture, “an automotive-industry first for a modern production diesel engine,” Ford claims. This change reduces overall exhaust system volume. Reduced exhaust system surface area minimizes heat transfer to the engine compartment and improves noise, vibration, and harshness (NVH.) The new design’s architecture is also seen easing service to major engine components. Overall, the new engine about 160 lb lighter than the V-8 it replaces. Its mid-deck construction with dual water jackets is said to increase strength and optimize cooling. With six head bolts it will have better sealing and cylinder integrity, even with the higher firing pressures.