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Diesel Engine Programs Driving CGI Progress

Jan. 29, 2019
Ram and F-150 engine demonstrate automakers’ embrace of SinterCast process results

Compacted graphite iron continues to make an impression in consumer markets thanks to diesel engine programs: the Ford Motor Co. 3.0-liter V6 turbodiesel engine for the F-150 pick-up earned a Wards’ 10 Best Engines award at this month’s North American International Auto Show (NAIAS), and a new, 6.7-liter in-line diesel engine was introduced there for the Ram Trucks’ Super Duty pick-up. Both engines are based on a CGI block produced using SinterCast process control technology.

Sintercast technology also continues to prosper with industrial diesel engine programs. China Shipbuilding Industry Corp. (CSIC) No. 12 Research Institute in Shaanxi Province, China, will be the site of a new SinterCast process installation during Q2.

SinterCast AB is the Stockholm-based developer of the most widely used technology for producing compacted graphite iron (CGI).

CGI is a lightweight cast iron that offers greater tensile strength, stiffness, and fatigue strength than gray iron or aluminum. It is mainly used by diesel and gas engine manufacturers seeking to reduce weight, noise, and emissions for their designs. The Wards honor for the Ford Power Stroke diesel engine means that for five straight years a SinterCast-CGI engine has been recognized among the 10 Best Engine award winners, the developer noted.

The F-150’s CGI V-6 engine was recognized as “a light-duty engine capable of remarkable fuel economy while towing heavy loads for work or pleasure.”

The new, 400-hp 6.7-liter engine in the Fiat Chrysler Automobiles pick-up will be cast at the Tupy foundry in Saltillo, Mexico, starting in 2Q 2019.

“The start of production of the Ram 6.7-liter diesel marks the first application of CGI for in-line diesels in a passenger vehicle application, delivering high-volume series production in each of the ‘Five Waves’ that SinterCast first presented in 2002,” stated Dr. Steve Dawson, president and CEO of SinterCast.

“As a replacement program for an existing engine, we anticipate a vertical ramp, potentially providing production of approximately 300,000 'engine equivalents' (15,000 metric tons) per year, and providing significant contributions to our target for double-digit growth in 2019 and to our campaign to break the three million engine-equivalent milestone.”

SinterCast reported it has started a "technology supply agreement" with CSIC No. 12, a ferrous foundry, for series production of CGI industrial power components. The Chinese group will install a Mini-System 3000 and wirefeeder and provide technical support to establish compacted-graphite iron production there. The mobile process-control unit will allow CSIC to produce CGI castings for current and prospective customers, in domestic and export industrial-power markets.